Laser-Welded Metal Jointing Without Clamp-Limited Weld Areas

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Solution Overview

Problem

The existing methods for manufacturing joint bodies by laser welding between two metal members face challenges in achieving uniform joint strength due to the need for clamping, which restricts the welding area and limits the overall strength of the joint.

Innovation Solution

A manufacturing method and apparatus where the second metal member is continuously supplied and pressed against the first metal member, eliminating the need for clamping and allowing for full laser welding, thereby increasing the joint strength between the two metal members.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the second metal member is clamped to the first metal member for laser welding, then the metal members can be held in position, but the clamped portion cannot be welded by laser and joint strength is reduced

Engineering Contradiction:

Improvejoint strengthVSAvoidwelding process

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Instead of clamping the second metal member to the first metal member (traditional approach), the invention inverts the approach by pressing the second metal member against the first metal member during continuous supply. This inversion eliminates the clamping restriction on the welding area while maintaining proper positioning, allowing the entire surface to be welded by laser and significantly increasing joint strength

Inventive Principle:

Principle #13The other way round (Inversion)

2Manufacturing precision

If the second metal member is clamped to the first metal member, then positioning is achieved, but the welding area is restricted and cannot be welded in its entirety

Engineering Contradiction:

Improvepositioning accuracyVSAvoidwelding area

Core Design Contradiction:

Manufacturing precisionVSArea of stationary object

Solution Approach 1:

The invention inverts the traditional clamping approach by using a pressing mechanism during continuous supply. This allows the second metal member to be positioned accurately against the first metal member while maintaining full accessibility for laser welding across the entire welding area, eliminating the restriction caused by clamps

Inventive Principle:

Principle #13The other way round (Inversion)

3Stability of the object's composition

If clamping is used to join the metal members, then positioning is maintained, but the overall joint strength cannot be increased

Engineering Contradiction:

Improvepositioning stabilityVSAvoidjoint strength

Core Design Contradiction:

Stability of the object's compositionVSStrength

Solution Approach 1:

By inverting from clamping to pressing during continuous supply, the invention achieves both positioning stability and enhanced joint strength. The pressing mechanism maintains proper alignment while allowing complete laser welding coverage, resulting in significantly stronger joints compared to clamped configurations

Inventive Principle:

Principle #13The other way round (Inversion)

4Strength

If the second metal member is continuously supplied and pressed against the first metal member, then the entire surface can be welded by laser, but a supplying mechanism is required

Engineering Contradiction:

Improvejoint strengthVSAvoidsupplying mechanism

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The invention employs dynamic continuous supply of the second metal member against the first metal member during welding. This dynamic approach enables full-surface laser welding and maximizes joint strength, with the supplying mechanism integrated into the manufacturing process flow

Inventive Principle:

Principle #15Dynamics

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 the entire surface of the second metal member to be welded, resulting in enhanced joint strength between the first and second metal members, suitable for reinforcing vehicle frame components.

Implementation Method 1

the second metal member is welded to the first metal member by laser

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Implementation Method 2

allows the entirety of the second metal member to be welded by laser

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentEP3677374B1Manufacturing method for join body and manufacturing apparatus for join body

Publication Date: 2023.01.04 KOBE STEEL LTD

Figure 1~2
Figure 3A
Figure 3B

AI summary

A manufacturing method for a joint body (1) having a first metal member (2) and a second metal member (3) joined together by causing a laser oscillation system (25) to irradiate a surface of the second metal member (3) placed on the first metal member (2) with laser light to form a joint portion (5) including a welded portion (4) where the first metal member (2) and the second metal member (3) are joined together includes continuously supplying the second metal member (3) while pressing the second metal member (3) against the first metal member (2), the second metal member (3) being a hoop material, and causing the laser oscillation system (25) to emit the laser light.