Laser Welded Resin Material With Closed Space Containment
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Solution Overview
Problem
Existing methods for producing welded resin materials using laser welding often result in excluded resin being dropped off or contaminating the environment, and require high energy and prolonged welding times, with issues related to contact surface planarity and durability.
Innovation Solution
A method involving superimposing resin members with transmissivity and absorptivity to laser light, forming a contact part and a closed space adjacent to it, and radiating laser light while pressing the members to melt and solidify the resin within the closed space, preventing the excluded resin from being dropped off.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If laser welding is performed to join resin members, then welding strength is improved, but excluded resin is dropped off and causes contamination
Solution Approach 1:
The patent converts the harmful excluded resin into a beneficial element by directing it into a mold cavity where it is shaped into a decorative pattern. The resin that would otherwise be waste is transformed into an aesthetic feature, eliminating contamination while utilizing the melting process effectively.
Solution Approach 2:
The patent introduces a mold cavity as an intermediary structure between the welding process and the environment. This cavity captures and contains the excluded resin, preventing it from dropping off and contaminating the surroundings while allowing the welding to proceed normally.
2Manufacturing precision
If high energy laser light is used to ensure complete filling of closed space, then welding completeness is improved, but energy consumption increases and welding time prolongs
Solution Approach 1:
The patent applies preliminary action by pre-forming the mold cavity in a position optimized for receiving molten resin. The cavity is strategically located to capture excluded resin naturally during the welding process, eliminating the need for excessive energy input to force-compress or redirect the resin.
Solution Approach 2:
The patent enables the system to be self-service by allowing the welding process itself to fill the mold cavity with excluded resin. The natural flow of molten resin during welding automatically populates the cavity without requiring additional energy input or complex control mechanisms.
3Manufacturing precision
If surrounding resin is melted excessively to fill closed space, then welding completeness is improved, but resin density decreases and durability deteriorates
Solution Approach 1:
The patent applies local quality by concentrating the melting process specifically at the contact interface where welding is needed, rather than melting the entire surrounding resin. The mold cavity is positioned to capture only the locally excluded resin, preventing excessive melting and preserving the density and durability of the bulk material.
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 method achieves excellent welding properties with reduced energy consumption, prevents resin contamination, and maintains product integrity by housing the molten resin within the closed space.
Implementation Method 1
a resin member having transmissibility to laser light having a specific wavelength
Implementation Method 2
a resin part having absorptivity to laser light having the same wavelength. The energy of the laser light thus absorbed is converted to heat
Implementation Method 3
irradiated with laser light from the side of the transmissive resin member
Implementation Method 4
The vicinity of the surface of the transmissive resin member, which is in contact with the surface of the absorptive resin member, is also heated through heat transfer
Implementation Method 5
a molten layer is formed at a part where the transmissive resin member and the absorptive resin member are in contact with each other
Data Source
AI summary
A method for producing a welded resin material contains steps of: superimposing a resin member having transmissibility to laser light and a resin member having absorptivity to laser light to form a contact part where the resin members are in contact with each other; forming a closed space that is adjacent to the contact part and faces one end of the contact part; and radiating the laser light from the resin member having transmissibility while pressing the resin members to each other through the contact part, so as to heat the contact part to melt a resin at the contact part, housing a resin excluded from the contact part through melting in the closed space, solidifying the resin melted at the contact part to weld the resin members.