Laser Welded Sealing Ring Production

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Solution Overview

Problem

Existing methods for producing sealing rings using sheet-metal strips face challenges such as poor surface quality, leakiness due to concave depressions from welding, and the need for flux in joining processes, which can lead to irregular surfaces and increased costs.

Innovation Solution

The method involves laser cutting and laser welding of sheet-metal strips to form sealing rings with precise edges and a high-quality weld seam, eliminating the need for flux and minimizing material changes, while allowing for various forms and surface profiles through roll-forming and calibration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welding or soldering is used to join edges of sheet-metal strip, then substance-to-substance bond is achieved, but concave depressions form at the join due to material creep causing leakiness

Engineering Contradiction:

Improvebond strengthVSAvoidsurface quality at join

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The invention changes the joining method from conventional welding/soldering to friction stir welding, which fundamentally alters the physical and chemical parameters of the joining process. This results in a protruding weld seam instead of concave depressions, eliminating the leakiness problem while maintaining bond strength.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces thermal joining processes (welding/soldering) with a mechanical joining process (friction stir welding). This substitution eliminates the material creep and concave depression formation associated with thermal processes, while achieving strong substance-to-substance bonding.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If soldering is used for joining, then substance-to-substance bond is achieved, but good capillary effect is only attainable when distance between edges is small and surfaces must be wettable

Engineering Contradiction:

Improvebond strengthVSAvoidjoining process complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The invention replaces the chemical/capillary-based soldering process with a mechanical friction stir welding process. This eliminates the requirements for small edge distances and surface wettability, simplifying the manufacturing process while achieving strong bonds.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If conventional cutting methods are used to cut sheet-metal strip, then ring is formed, but fracture surfaces extend obliquely requiring flux during subsequent welding

Engineering Contradiction:

Improvering formationVSAvoidwelding preparation

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The invention replaces conventional mechanical cutting with laser cutting, which produces clean, perpendicular edges without oblique fracture surfaces. This eliminates the need for flux during subsequent friction stir welding, simplifying the manufacturing process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Manufacturing precision

If high energy is input over small cross section during welding, then small zone of molten material is created with slight microstructural change, but welding tool wear occurs

Engineering Contradiction:

Improveweld seam qualityVSAvoidtool wear

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The invention replaces conventional welding tools that suffer from wear with a laser beam system. The laser creates the weld through optical energy without physical contact, eliminating tool wear while maintaining high weld seam quality and precise control of the molten zone.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 high-quality, uniform weld seams, reduced material deformation, and cost-effective production with precise dimensional accuracy, enhancing the sealing performance and manufacturing efficiency of sealing rings.

Implementation Method 1

the sheet-metal strip being cut to the length of the ring circumference by laser cutting

Methodology Applied

Scientific EffectLaser cutting: Laser Ablation

Implementation Method 2

the mutually contacting edges of the sheet-metal strip being joined together by laser welding in a substance-to-substance bond

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Implementation Method 3

The post-deformation can be accomplished by roll-forming or deep-drawing

Methodology Applied

Scientific EffectRoll-forming: Plasticity

Data Source

PatentUS9816615B2Method for the production of a sealing ring

Publication Date: 2017.11.14 CARL FREUDENBERG KG

AI summary

A method for producing a sealing ring comprises cutting a sheet-metal strip to a length of a ring circumference using laser cutting; forming the sheet-metal strip into a ring shape having first and second mutually contacting edge surfaces; and joining the first and second mutually contacting edges using laser welding so as to form a substance-to-substance bond.