Laser Welded Scanner Assemblies Overcoming Magnetic Separation
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Solution Overview
Problem
Current scanning laser devices face challenges in achieving high performance and low cost due to limitations in the size and manufacturing efficiency of scanner assemblies that house and power scanning mirrors, particularly with strong magnets causing separation issues during assembly.
Innovation Solution
The use of plastic bodies with welded coupling structures, including a movable scanning platform and a drive device, facilitates improved manufacturing yields, reduced costs, and increased performance by employing laser welding through a mask to create strong bonds between plastic bodies, eliminating the need for clamping and minimizing damage during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional assembly methods are used to assemble scanner assemblies with strong magnets, then the assembly process is simple, but the magnets cause separation issues during assembly reducing manufacturing yield
Solution Approach 1:
The patent replaces mechanical fastening methods with laser welding to join the first and second plastic bodies. This substitution eliminates the separation issues caused by strong magnets during mechanical assembly, as welding creates a permanent bond that is not affected by magnetic forces. The laser welding process directly fuses the plastic materials at the coupling structures, providing reliable joining without the need for clamping or mechanical fasteners that would be disrupted by magnetic separation.
Solution Approach 2:
The laser welding process utilizes phase transitions of the plastic material during joining. The laser energy heats the plastic at the coupling structures, causing localized melting (phase change from solid to liquid), and subsequent cooling solidifies the melted plastic to form a strong bond between the first and second plastic bodies. This phase transition mechanism enables permanent joining that overcomes magnetic separation forces.
2Strength
If laser welding is used to join plastic bodies, then bonding strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent incorporates coupling structures that are integrated into the plastic bodies during molding. These coupling structures are segmented features (such as protrusions or recesses) that are pre-formed as part of the plastic body manufacturing process. By segmenting the joining interface into these predefined coupling structures, the laser welding process is simplified to only need to join these specific features rather than entire surfaces, reducing manufacturing complexity while maintaining strong bonding.
Solution Approach 2:
The coupling structures are preliminarily formed into the first and second plastic bodies during the molding process before the laser welding step. This preliminary action of pre-positioning and pre-shaping the joining features eliminates the need for complex alignment and preparation steps during laser welding, reducing manufacturing process complexity while ensuring proper bonding geometry for strong joints.
3Reliability
If multiple coupling structures are welded, then assembly reliability is improved, but manufacturing time increases
Solution Approach 1:
The patent merges multiple welding operations into a single integrated laser welding process. The laser system is configured to weld multiple coupling structures (first, second, third, and fourth coupling structures) in sequence or simultaneously during one continuous manufacturing operation. By merging these welding steps into a single process flow without intermediate handling or repositioning, the patent achieves high assembly reliability through multiple welded joints while minimizing the increase in manufacturing time.
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 results in scanner assemblies with enhanced bonding strength, reduced manufacturing time, and increased reliability, enabling the production of high-performance scanning laser devices at lower costs while overcoming separation forces caused by strong magnets.
Implementation Method 1
welded to the second plastic body by a laser beam through a mask
Implementation Method 2
laser welding through a mask to create strong bonds between plastic bodies
Data Source
AI summary
The embodiments described herein provide improved scanner assemblies that include a first plastic body, a second plastic body, a movable scanning platform and a drive device. The first plastic body includes a first plurality of coupling structures, while the second plastic body includes a second plurality of coupling structures. The moveable scanning platform is positioned between the first plastic body and the second plastic body, and each of the first plurality of coupling structures is welded to a corresponding one of the second plurality of coupling structures.