Laser Welded Diaphragm Blade Using Transmissive Shaft
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Solution Overview
Problem
Existing diaphragm blades for cameras face challenges in achieving precise dimensional accuracy and cost-effectiveness due to issues with shaft thickness, resin flowability, and increased load on blade drivers, leading to larger apparatus sizes and manufacturing complexities.
Innovation Solution
The use of a thin-plate blade member made of laser absorptive resin and a shaft member made of laser transmissive resin, where the blade member is welded to the shaft member using a laser beam transmitted through the shaft member, allowing for precise welding without deformation and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the shaft portion is increased to improve welding strength, then the resin flowability improves, but the dimensional accuracy of the shaft portion deteriorates due to deformation
Solution Approach 1:
The patent employs a composite material structure where the shaft portion is made of laser-transmissive resin and the blade base is made of laser-absorptive resin. This material differentiation enables selective laser heating during welding, allowing the laser beam to pass through the shaft portion without deforming it, while effectively heating and welding the blade base. This resolves the contradiction by maintaining shaft portion dimensional accuracy while achieving sufficient welding strength.
2Force
If the thickness of the blade base is increased to reduce load during drive, then the drive reliability improves, but the apparatus size increases requiring larger motors
Solution Approach 1:
The patent optimizes the thickness parameter of the blade base to a specific range (0.05-0.2 mm) that balances drive load requirements with apparatus size constraints. By precisely controlling this parameter and combining it with the laser welding process, the invention achieves sufficient structural strength without requiring excessive thickness, thereby maintaining compact apparatus dimensions while ensuring drive reliability.
3Ease of manufacture
If mechanical caulking or outset molding is used to attach the shaft, then the manufacturing process is established, but the number of man hours increases and reliability problems occur due to protruding marks
Solution Approach 1:
The patent replaces mechanical attachment methods (caulking, outset molding) with laser beam welding. This substitution eliminates the need for mechanical fastening processes that create protruding marks and require extensive manual operation. The laser welding process directly fuses the shaft portion to the blade base through selective heating, achieving reliable attachment with reduced manufacturing complexity and improved reliability.
4Shape
If the number of diaphragm blades is increased to obtain a circular aperture, then the aperture quality improves, but the manufacturing cost increases
Solution Approach 1:
The patent employs laser beam welding, an automated process that enables precise and consistent welding of multiple diaphragm blades without requiring extensive manual intervention. The laser system can automatically position and weld each blade to its shaft portion, facilitating the manufacturing of multi-blade assemblies with circular apertures while controlling manufacturing costs through automation and process efficiency.
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 enhances dimensional accuracy, reduces the size of the apparatus, and lowers manufacturing costs by ensuring a strong and precise weld without protrusions, thereby improving the overall performance and efficiency of the diaphragm blades.
Implementation Method 1
The blade member is welded to the shaft member with laser beam transmitted through the shaft member
Implementation Method 2
The blade member is welded to the shaft member with laser beam transmitted through the shaft member
Implementation Method 3
The blade member is made of laser absorptive resin, whereas the shaft member is made of laser transmissive resin
Data Source
AI summary
A diaphragm blade includes a light-shielding, thin-plate blade base made of laser absorptive resin to regulate an aperture, and a first shaft portion made of laser transmissive resin and provided on one surface of the blade base. The first shaft portion includes a cylindrical member which is welded to the protruding weld portion, a protruding weld portion integrally formed with the blade base, and a recess formed at the back side of the protruding weld portion. The cylindrical member has a first recess defined at one end thereof near the blade base and coming into contact with the protruding weld portion, and a second recess defined at the other end. A contact surface of the protruding weld portion is melted with laser beam transmitted through the cylindrical member, whereby the protruding weld portion is welded to the cylindrical member.