Laser-Welded Plastic Segments for Hermetic Mold Assembly
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Solution Overview
Problem
The current process for bonding plastic segments in stator and wheel type products is labor-intensive and difficult to achieve specific customer requirements, often resulting in dimensional and sealing issues that require rework, especially when using manual methods and chemical bonding agents.
Innovation Solution
The use of laser welding to bond plastic segments with redesigned protruding portions that form a single bump seam, eliminating the need for secondary processing to fill concave areas and maintaining original dimensions, thereby achieving a hermetic seal without shrinkage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual bonding with chemical agents is used, then assembly can be performed, but the process becomes labor-intensive and requires secondary processing to fill concave areas
Solution Approach 1:
The patent replaces chemical bonding agents with laser welding technology. The laser beam melts and fuses the plastic segments directly, eliminating the need for chemical adhesives and the associated manual application processes. This substitution of chemical-mechanical bonding with optical-thermal welding resolves the contradiction by automating the bonding process while eliminating labor-intensive secondary operations.
Solution Approach 2:
The patent modifies the geometric parameters of the segment interfaces by designing protruding portions that extend beyond the segment surfaces. These protrusions are engineered to melt and fuse together during laser welding, automatically filling concave areas and creating convex seams. This parameter change eliminates the need for secondary filling operations and resolves the productivity issue.
2Strength
If chemical bonding agents are used, then segments can be joined, but dimensional precision and seal quality become difficult to control
Solution Approach 1:
The patent replaces chemical bonding with laser welding, which provides precise control over the bonding process through programmable laser parameters (power, speed, focal position). This substitution enables consistent dimensional accuracy and seal quality by eliminating the variability associated with manual chemical application and curing processes.
Solution Approach 2:
The patent incorporates protruding portions in the segment design that are pre-configured to melt and fuse together during welding. This preliminary geometric configuration ensures that the bonding process automatically achieves the required dimensional precision and seal integrity without requiring post-bonding adjustments or fill operations.
3Reliability
If concave areas are filled manually, then seals can be improved, but additional processing time and labor are required
Solution Approach 1:
The patent designs protruding portions that extend beyond the segment surfaces, which are pre-configured to melt and fuse together during the laser welding process. This preliminary geometric configuration ensures that the bonding process automatically fills concave areas and creates convex seams, eliminating the need for post-bonding fill operations and reducing total processing time.
Solution Approach 2:
The patent merges the bonding operation with the seal-filling operation into a single laser welding process. The laser simultaneously welds the segments together and melts the protruding portions to fill concave areas, creating both structural bonds and sealed surfaces in one step. This merging resolves the contradiction by achieving both seal quality and time efficiency.
4Productivity
If laser welding is used with traditional flat interfaces, then bonding speed increases, but concave areas remain requiring secondary processing
Solution Approach 1:
The patent introduces asymmetric protruding portions at the segment interfaces that break the traditional flat symmetry. These protrusions are designed to melt and fuse together during laser welding, creating continuous convex surfaces. The asymmetric geometry enables the laser to maintain high welding speed while automatically filling concave areas and achieving surface continuity without secondary processing.
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
Laser welding effectively seals and bonds plastic segments, reducing the need for post-processing and rework, maintaining original dimensions, and enhancing the repeatability and cost-effectiveness of the assembly process by eliminating human error and secondary processing steps.
Implementation Method 1
laser welding to bond plastic segments with redesigned protruding portions that form a single bump seam
Implementation Method 2
Laser welding effectively seals and bonds plastic segments
Implementation Method 3
laser welding to bond plastic segments with redesigned protruding portions that form a single bump seam, eliminating the need for secondary processing to fill concave areas and maintaining original dimensions, thereby achieving a hermetic seal
Data Source
AI summary
The present disclosure relates to methods and components for the bonding together of plastic components during a manufacturing and/or assembly process to create molds for lost-wax casting.