Laser-Welded Connection Housings for High Shear Strength
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Solution Overview
Problem
Existing electrical connection arrangements between adjacent housings suffer from low mechanical stability and strength, leading to potential detachment under stress.
Innovation Solution
A strip-shaped connecting profile made of laser-transparent material is permanently fastened to adjacent connection housings using a laser welding process, enhancing mechanical strength and flexural rigidity, with defined welding surfaces and guide features for precise positioning and secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pins are used to connect terminal housings, then the connection can be assembled easily, but the mechanical stability and strength are low
Solution Approach 1:
The patent replaces the mechanical pin connection system with a laser welding system. The connecting profile is permanently attached to the terminal housings using laser welding, which provides superior mechanical strength while maintaining assembly efficiency through automated welding processes. This substitution transitions from mechanical interlocking to thermal bonding, resolving the contradiction between ease of assembly and mechanical strength.
2Device complexity
If adhesive connection is used, then the connection can be simple, but it cannot absorb high shear forces
Solution Approach 1:
The patent replaces adhesive bonding with laser welding to achieve permanent attachment of the connecting profile. Laser welding creates a metallurgical bond that can absorb high shear forces, while maintaining process simplicity through direct welding without requiring adhesive application, curing time, or surface preparation. This resolves the contradiction by providing both simplicity and high force resistance.
3Strength
If a permanent connection is made between connecting profile and connection housings, then mechanical strength is improved, but distortion may occur during welding
Solution Approach 1:
The patent utilizes laser welding parameters (high energy density, concentrated heat input, short welding time) to achieve permanent connection while minimizing thermal distortion. The laser welding process allows precise control of thermal parameters, enabling strong welds with reduced heat-affected zones. This resolves the contradiction by optimizing welding parameters to achieve both high strength and minimal distortion.
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
The solution provides a highly stable and secure connection that can withstand high shear forces and deflection stress, ensuring the connection housings remain firmly attached without distortion.
Implementation Method 1
The connecting profile is permanently attached to the connection housings by means of a laser welding process
Implementation Method 2
The connecting profile is preferably welded to the connection housings using a laser transmission welding process
Data Source
Figure 1~2
Figure 3~4C
AI summary
The invention relates to an electrical connection arrangement (100), having at least two connection housings (10) arranged adjacent to one another and at least one strip-like connecting profile (15) for inseparably connecting the adjacent connection housings (10), wherein the connecting profile (15) spans the adjacent connection housings (10) and the connecting profile (15) is fastened inseparably to the adjacent connection housings (10) by means of a laser welding method.