Laser-Welded Aluminum Door and Window Frame Joints
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Solution Overview
Problem
Existing door/window fixtures made of aluminum or its alloys suffer from mechanical connection weaknesses over time, leading to deformation and difficulty in opening and closing, and visible joint lines that affect aesthetic appearance.
Innovation Solution
A door/window fixture with laser-welded joints between profiles and brackets made of the same aluminum alloy, ensuring uniform melting and reinforcement without visible seams, and incorporating thickened walls for additional structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical connection brackets are used to join aluminum profiles, then the fixture can be assembled and disassembled, but the connection strength decreases over time due to weight and repeated operations
Solution Approach 1:
The patent combines mechanical bracket connection with laser welding to create a hybrid joint system. The bracket provides initial mechanical alignment and support, while the laser weld creates a permanent metallurgical bond that prevents loosening over time. This merging of reversible mechanical connection with irreversible thermal connection resolves the contradiction between assembly ease and long-term reliability.
Solution Approach 2:
The joint system uses a composite approach combining two different connection methods (mechanical bracket + laser weld) to achieve properties that neither method alone can provide. The mechanical bracket offers ease of installation and positioning, while the laser-welded aluminum-to-aluminum joint provides superior strength and durability, creating a composite connection system.
2Ease of manufacture
If profiles are cut at 45° or 90° for mechanical connection, then assembly is facilitated, but visible joint lines appear that affect aesthetic appearance
Solution Approach 1:
The laser welding process creates weld seams that match the color and appearance of the surrounding aluminum profile material. By using the same aluminum alloy for both the profile and the filler material, the weld becomes visually indistinguishable from the base material, effectively hiding the joint lines while maintaining the benefits of mechanical assembly.
3Reliability
If the fixture is made robust with reinforced connections, then durability improves, but the material consumption and manufacturing complexity increase
Solution Approach 1:
The patent replaces purely mechanical fastening systems with laser welding, which uses thermal energy to create metallurgical bonds. This substitution eliminates the need for additional fasteners, seals, and adjustment mechanisms, reducing overall manufacturing complexity while achieving superior connection strength and durability.
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 enhances the mechanical strength and durability of the fixture, maintaining smooth operation and improving aesthetic quality by eliminating visible joints and reinforcing connections.
Implementation Method 1
comprises a first additional laser-welded joint between the first and second profiles and/or a second additional laser-welded joint between at least one of said first and second profiles and the bracket
Implementation Method 2
using the same material allows the laser welding process to melt the bracket and both profiles uniformly
Implementation Method 3
said thickened walls have a minimum thickness between 2 and 3 times greater than the minimum thickness of the visible walls of the metallic profiles
Data Source
AI summary
A fixture for a door or window includes a fixed frame and a movable frame. At least one of the fixed frame or the movable frame includes a first metal profile made of aluminum or aluminum alloy, a second metal profile also made of aluminum or aluminum alloy, and at least one laser joint between the first profile and the second profile. A mechanical joint may also be provided between the first profile and the second profile. The mechanical joint including a metal bracket made of aluminum or aluminum alloy.