Laser-Welded Cable and Hose Feedthroughs Without Shading
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Solution Overview
Problem
Existing push-through connection methods for electrical cables and fluid-carrying hoses in plastic components face challenges in achieving quick and reliable sealing, especially when multiple connections are needed next to each other, as they require complex manufacturing processes and are hindered by shading issues that restrict radial laser welding.
Innovation Solution
A method involving a plastic component with prefabricated openings, where electrical cables or fluid-carrying hoses are inserted and thermally welded using two opposing laser beam units moved linearly to create a simultaneous and efficient sealing connection, allowing access to inner areas and overcoming shading limitations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If radial laser welding is used for through-connections, then sealing and fixation are achieved through surface melting, but the laser beam cannot be directed to connection points without obstruction when multiple connections are needed next to each other
Solution Approach 1:
The patent transitions from radial laser welding (single-direction approach) to linear laser welding (opposing bidirectional approach). Two laser beam units are positioned opposite each other and move linearly along the openings, enabling welding access from both sides of the component simultaneously. This dimensional change in the welding approach eliminates shadowing issues and allows multiple adjacent connections to be made without obstruction.
Solution Approach 2:
The welding process is segmented into two opposing laser beam units that work simultaneously from opposite sides of the component. Each laser beam unit handles a portion of the welding task, and their combined action achieves complete sealing and fixation. This segmentation allows the laser beams to access connection points that would be shadowed in a single-direction approach.
2Productivity
If multiple through-connections are made directly next to each other, then complete cable routing is achieved, but the laser beam units cannot access all connection points due to shadowing from adjacent cables and components
Solution Approach 1:
By positioning laser beam units on opposite sides of the component and moving them linearly along the openings, the patent enables all connection points to be accessed simultaneously from both directions. This eliminates the shadowing problem that occurs when multiple cables are arranged adjacent to each other in a single-direction welding approach.
Solution Approach 2:
The laser beam units are pre-positioned opposite each other and aligned with the openings before the welding process begins. This preliminary positioning ensures that all connection points are accessible from the start, allowing multiple adjacent connections to be made without repositioning or obstruction during the welding process.
3Reliability
If quasi-simultaneous welding is used with the laser beam passing over the joint multiple times in alternating passes, then the joint heats up and welds almost simultaneously, but the process is time-consuming and complex
Solution Approach 1:
The patent employs simultaneous welding from two opposing laser beam units that move continuously along the openings in a linear fashion. Both laser beams are active at the same time, heating and welding the joint continuously as they move, eliminating the need for multiple alternating passes. This continuous action from both sides achieves reliable welding in a single pass, significantly reducing cycle time.
Solution Approach 2:
The laser beam units are pre-positioned and synchronized to move together along the openings, establishing optimal heating conditions from both sides simultaneously before the welding process begins. This preliminary synchronization ensures continuous and uniform heating throughout the joint, achieving reliable weld quality in a single continuous operation rather than multiple passes.
4Reliability
If a cup-shaped guide piece with thermoplastic material is used to fill the opening cross-section, then a sealed multi-hole connection is formed, but the various successive process steps result in relatively high manufacturing cost
Solution Approach 1:
The patent removes the cup-shaped guide piece and thermoplastic filling material from the process, replacing them with direct laser welding of the cable sheaths to the plastic component. This extraction of unnecessary intermediate components and process steps simplifies the manufacturing process while maintaining sealing quality through the material-bonded connection achieved by laser-induced melting.
Solution Approach 2:
The patent replaces the mechanical filling and sealing process (cup-shaped guide piece with thermoplastic material) with a thermal process (laser welding). Instead of mechanically inserting and filling material, the laser beam directly melts and bonds the cable sheaths to the component, achieving sealing through thermal fusion rather than mechanical filling. This substitution reduces process complexity and manufacturing cost.
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 enables time-saving, reliable, and simultaneous welding of multiple push-through connections without the need for rotary movements, ensuring efficient sealing and reducing manufacturing complexity.
Implementation Method 1
the opposing laser beam units are activated and moved in a linear direction along the series of openings, so that the material-locking connection is created after cooling by melting the surfaces of the materials to be joined
Implementation Method 2
at least two opposing laser beam units are aligned on their respective initial connection points, after which the opposing laser beam units are activated and set into a linear relative movement perpendicular to the direction of the openings, in order to create the material-bonded connection by melting the thermoplastic coating with the thermoplastic plastic component on the surface
Implementation Method 3
the material-locking connection is created after cooling by melting the surfaces of the materials to be joined
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a method and to an apparatus for producing a plug-through connection arrangement of a plurality of electrical cables (1a-1d) and/or fluid-conducting hoses, having a sheathing (2) consisting of a plastic, which extend, arranged adjacently spaced apart from each other, through associated openings (3a-3d) of a plastic component (4), comprising the following steps: providing (A) the plastic part (4) with the pre-produced plurality of openings (3a-3d), installing (B) the electrical cables (1a-1d) and/or fluid-conducting hoses through the associated openings (3a-3d), such that the outer wall of the sheathing (2), which consists of plastic, comes into contact with the inner wall of the respective openings (3a-3d) of the plastic component (4), thermal welding (C) of the electrical cables (1a-1d) and/or fluid-conducting hoses to the plastic component (4) in the region of the respective opening (3a-3d), in order to produce an integrally sealing component bond, wherein at least two laser beam units (5a, 5b), positioned opposite each other, are aligned to an associated initial connection point, after which the oppositely positioned laser beam units (5a, 5b) are activated and caused to undergo a linear relative movement crosswise to the orientation of the openings (3a-3d), in order to create the integral bond by surface melting of the sheathing (2) together with the plastic component (4).