Laser Weld Clamping for Gap-Free Thin Conductor Joints
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Solution Overview
Problem
Thin conductor supports in electronics and battery manufacturing face challenges in achieving stable and reproducible laser welding due to thermal expansion, which can create gaps and variable heat input, leading to unreliable connections.
Innovation Solution
A method involving a clamping device that applies punctiform or linear force to ensure a nearly gap-free joining area, utilizing thermal expansion to solidify the first component against the second, with controlled laser beam movement and power variation for heat conduction welding, potentially transitioning to deep welding for enhanced penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a thin conductor support is used, then the component can be manufactured with reduced thickness, but thermal expansion during welding creates gaps that compromise connection reliability
Solution Approach 1:
The clamping device applies force to the conductor support before the laser welding begins, pre-positioning the thin component against the substrate to eliminate gaps that would otherwise form during thermal expansion. This preliminary mechanical constraint ensures stable contact is maintained throughout the welding process.
Solution Approach 2:
The system dynamically adjusts the clamping force parameter during the welding process to compensate for thermal expansion. By modifying the mechanical constraint parameter in response to temperature changes, the thin conductor support remains in stable contact with the substrate despite thermal effects.
2Reliability
If uniform clamping force is applied across the entire conductor support, then stable contact is achieved, but the thermal expansion effect cannot be utilized to close gaps
Solution Approach 1:
The clamping device applies force locally at specific positions on the conductor support rather than uniformly across the entire component. This localized clamping allows the thin conductor support to thermally expand and close gaps in the joining area while maintaining stable contact at the clamped positions.
Solution Approach 2:
The clamping force is segmented into discrete application points rather than continuous uniform pressure. This segmentation allows different regions of the conductor support to have different mechanical constraints, enabling gap closure through thermal expansion in non-clamped regions while maintaining stability at clamped regions.
3Productivity
If the laser beam moves quickly to maintain productivity, then manufacturing efficiency increases, but heat input becomes variable leading to inconsistent weld quality
Solution Approach 1:
The system incorporates feedback control where the actual welding speed and heat input are monitored and adjusted in real-time. This feedback mechanism ensures that even at high welding speeds, the heat input remains consistent and within the optimal range for producing uniform weld seams.
Solution Approach 2:
The laser beam operates in a periodic pulsed manner rather than continuous irradiation. This periodic action allows for controlled heat accumulation and dissipation cycles, maintaining consistent heat input even at high overall welding speeds, and preventing thermal runaway that would compromise weld quality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach ensures a stable and reliable laser weld seam by minimizing initial gaps and optimizing heat input, resulting in a homogeneous and gap-free connection with reduced spatter, suitable for mass production in electronics and battery manufacturing.
Implementation Method 1
it is heated by the laser beam and bulges in the direction away from the second component due to the thermal expansion
Implementation Method 2
the two components are connected to one another by fusing the material of at least one component with the aid of a laser beam and subsequently solidifying the melt
Data Source
AI summary
A method for connecting two components with the aid of a laser weld seam. The two components are situated one above the other in a joining area. The first component is pressed in the direction of the second component with the aid of a clamping device. A laser beam impacts the first component on the side facing away from the second component and at least indirectly fusing material of the two components.