Laser-Welded Drive Disc Coating for Moisture-Proof Floor Cleaning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing traction sheaves for floor cleaning machines face issues with adhesive coatings detaching due to forces and moisture, leading to loose spots and potential germ nests, especially in hygienic environments like clinics and hospitals, as conventional attachment methods like gluing and double-sided adhesive tape are not optimal.
Innovation Solution
A traction sheave with an adhesive coating made of a plastic material transparent to laser beams is laser-welded to the sheave, eliminating the need for additional adhesives and preventing moisture penetration, using a plastic material that absorbs laser beams for a strong and durable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive coatings are attached to the traction sheave using conventional methods (gluing, double-sided adhesive tape, clamps), then the attachment process is simple and cost-effective, but the adhesive coating detaches during operation due to forces and moisture penetration
Solution Approach 1:
The patent replaces mechanical attachment methods (gluing, taping, clamping) with laser welding technology. The adhesive coating and traction sheave are made of laser-weldable plastic materials, allowing direct welding without additional adhesives or mechanical fasteners. This substitution eliminates the detachment problems associated with conventional methods while maintaining manufacturing efficiency.
Solution Approach 2:
The patent changes the material parameters of the adhesive coating and traction sheave to be compatible with laser welding. Both components are made of plastic materials that can be welded using laser technology, enabling a permanent bond that resists operational forces and moisture penetration that cause detachment in conventional attachment methods.
2Strength
If additional adhesives or double-sided adhesive tape are used to attach the adhesive coating, then the attachment strength is improved, but moisture can still penetrate between layers leading to germ nest formation
Solution Approach 1:
The patent replaces adhesive-based attachment with laser welding, creating a direct fusion bond between the adhesive coating and traction sheave. This welding process eliminates the layered structure that allows moisture penetration in conventional methods, forming a seamless connection that prevents water and germ nest formation while maintaining or enhancing attachment strength.
Solution Approach 2:
The patent uses composite plastic materials that are compatible with laser welding. The adhesive coating and traction sheave are both made of laser-weldable plastics, creating a homogeneous welded joint that prevents moisture infiltration. This material selection ensures both strong attachment and resistance to harmful factors like moisture and germ formation.
3Object-affected harmful factors
If laser welding is used to attach the adhesive coating to the traction sheave, then moisture penetration is prevented and germ nest formation is eliminated, but the manufacturing process becomes more complex and expensive
Solution Approach 1:
The patent introduces laser welding technology to replace conventional attachment methods. While laser welding equipment represents an investment, the process eliminates the need for multiple steps involving adhesives, surface preparation, and quality inspection of bonded joints. The direct welding process simplifies the overall manufacturing workflow and provides immediate visual confirmation of successful attachment.
Solution Approach 2:
The patent selects plastic materials for both the adhesive coating and traction sheave that are optimized for laser welding. These materials have specific properties that enable efficient welding with standard laser equipment, reducing process complexity. The material selection allows for controlled welding parameters that ensure consistent results without requiring complex process control systems.
4Adaptability or versatility
If conventional attachment methods are used, then no special material requirements are needed, but the adhesive coating and traction sheave detach under operational forces
Solution Approach 1:
The patent specifies plastic materials for the adhesive coating and traction sheave with properties optimized for laser welding and force resistance. These materials have appropriate melting points, weldability, and mechanical strength to withstand operational forces. The material parameters are selected to ensure that the welded joint is stronger than the operational loads applied during floor cleaning operations.
Solution Approach 2:
The patent replaces adhesive-based force transmission with direct laser-welded mechanical fusion. The welded joint creates a monolithic structure that distributes operational forces across the entire bond area, preventing the localized stress concentrations that cause detachment in adhesive-based systems. This substitution provides superior force resistance while maintaining material flexibility.
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 laser-welded connection ensures a permanent and moisture-proof attachment of the adhesive coating, preventing germ formation and reducing environmental impact, while maintaining the integrity of the traction sheave and adhesive coating during cleaning processes.
Implementation Method 1
the adhesive coating or the traction sheaves are made of a plastic material that is transparent to laser beams and the traction sheave or the adhesive coating is made of a plastic material that absorbs laser beams
Implementation Method 2
the adhesive coating is at least partially laser-welded to the traction sheave
Implementation Method 3
In the boundary area between the traction sheave and the adhesive coating, at least the material of the traction sheave is consequently melted, which is permanently connected to the material of the adhesive coating
Data Source
Figure 1~2
AI summary
The disk (10) has an adhesive coating (15) i.e. check plate, provided at a lower side of the disk. The adhesive coating and the disk are formed from laser beam permeable plastic material, and/or laser beam absorbing plastic material. The coating is laser welded with the disk at inner and outer end regions (16, 18) of the coating along extensively closed lines (20, 22). The coating is formed from highly-modified polypropylene, and the disk is formed of laser beam absorbing polypropylene-homopolymer.