Laser-Welded Corner Connections for Coated Metal Profiles
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Solution Overview
Problem
Conventional welded corner connections in window, door, and facade constructions result in unsightly weld seams and damage to coatings, requiring significant recoating efforts and compromising aesthetic and functional appeal.
Innovation Solution
The use of laser-welded connections between coated metal profiles, which minimizes visible damage to the coating and allows for precise heat input, enabling the creation of dimensionally stable and visually appealing corner connections with reduced weld seam protrusion, using techniques such as indirect welding via corner connector angles and direct welding with minimal material addition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional fuel-based welding processes are used to join metal profiles, then the welding process is simple and well-established, but the metal profiles exhibit tarnishing and wide unsightly weld seams that require significant recoating efforts
Solution Approach 1:
The patent replaces conventional fuel-based welding processes with laser welding technology. This substitution enables precise heat input control, resulting in narrow weld seams with minimal coating damage and no tarnishing, thereby resolving the contradiction between manufacturing precision and ease of manufacture
Solution Approach 2:
The patent changes the thermal parameters of the welding process by using laser welding instead of conventional welding. This results in concentrated heat input with precise control, producing weld seams with minimal protrusion and minimal coating damage, thus improving weld appearance and reducing recoating requirements
2Manufacturing precision
If welding consumables are used to join metal profiles, then the welding process is straightforward, but the coating material burns off due to contact with the welding consumable
Solution Approach 1:
The patent replaces conventional welding with laser welding, eliminating the need for welding consumables that contact and burn off coating material. The laser beam provides contactless heating, preserving coating integrity at the weld area while maintaining process simplicity
3Manufacturing precision
If wide weld seams are produced by conventional welding, then the connection strength is sufficient, but the corner joints are visually and haptically unappealing and require sanding and recoating
Solution Approach 1:
The patent changes the thermal parameters of the welding process to produce narrow weld seams with minimal protrusion. This eliminates the need for sanding and extensive recoating work, thereby improving weld appearance while increasing productivity by reducing post-processing requirements
Solution Approach 2:
The patent converts the potential harm of heat-affected zone into a benefit by using precise laser welding control. The concentrated heat input creates a narrow heat-affected zone that minimizes coating damage and produces aesthetically pleasing narrow weld seams, eliminating the need for extensive post-processing
4Strength
If protruding welds are created by conventional welding, then the structural connection is robust, but the window or door closing is impeded and seals experience increased mechanical stress
Solution Approach 1:
The patent changes the dimensional parameters of the weld seam by using laser welding to produce narrow welds with minimal or no protrusion. This maintains structural connection strength while eliminating interference with window or door closing operations and reducing mechanical stress on seals
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
Laser-welded connections provide a visually and tactically appealing, dimensionally accurate corner connection with reduced mechanical load on seals, preventing unwanted protrusions and allowing for easy coating restoration, thus enhancing the overall appearance and functionality of the constructions.
Implementation Method 1
Laser welding enables dimensionally accurate and precise heat input
Implementation Method 2
a painted area can be formed as a burn-off zone, which contains products of the thermal decomposition of the paint in the painted area
Data Source
Figure 1~2
Figure 3~4
Figure 5a~5f
AI summary
A window, door and/or facade construction comprising a corner connection (50, 60, 70) with two metal profiles (1, 2) connected to each other by one or more welded joints (6, 7, 6', 7', 10, 10', 11, 11', 33), wherein the welded joint or welded joints (6, 7, 6', 7', 10, 10', 11, 11', 31, 33) is designed as a laser-welded joint, wherein the welded joint and/or welded joints (6, 7, 6', 7', 10, 10', 11, 11', 33) connects the profiles (1, 2) to each other indirectly by means of a corner connector angle (12, 16, 32), wherein the profiles (1, 2) particularly preferably each have profile chambers (8, 9), wherein the Corner connector angle (12, 16, 32) having at least two legs which are inserted into the profile chambers (8, 9), and a method for producing a corner connection (50, 60, 70) of a window, door and/or facade construction, preferably according to one of the preceding claims.with the following steps: a) Providing two metal profiles (1, 2), preferably coated metal profiles, and positioning both metal profiles (1, 2) at an angle to each other; the provision is carried out by inserting one leg of the corner connector angle (12, 16, 32) into a profile chamber (8, 9) of the respective metal profile (1, 2), so that one leg of the corner connector angle (12, 16, 32) is arranged in each of the two metal profiles (1, 2); and b) welding both metal profiles (1, 2) using a laser welding device, in particular a fiber laser welding device, wherein the power of the laser welding device is set such that a weld joint (6, 7, 6' ,7', 10, 10', 11, 11', 31, 33) is provided that welds through one profile wall, such that at least one, preferably through-welded, weld joint (6, 7, 6' ,7', 10, 10', 11, 31, 33) is formed between each metal profile (1, 2) and the corner connector angle (12, 16, 32).11', 33) is arranged.