Laser Welded Spherical Plate Structure with Thinned Joining Part
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Solution Overview
Problem
Existing methods for joining a metal ball to a flat plate using laser welding do not effectively address the challenge of reducing laser output and spatter generation when a spherical surface part is welded to the end face of a plate-shaped member, particularly in applications like gimbal springs where thickness and spring characteristics are critical.
Innovation Solution
A welded structure is formed by creating a thinner joining part on the plate-shaped member with a contact end face that matches the spherical surface part, allowing for reduced laser output and minimized spatter generation through precise laser irradiation, and a manufacturing method that involves laminating plate-shaped members to achieve the desired thickness and aspect ratio for gimbal springs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a spherical surface part is welded to an end face of a plate-shaped member using conventional laser welding methods, then the joining strength is achieved, but high laser output is required and spatter generation occurs
Solution Approach 1:
The patent applies preliminary action by forming a through-hole in the plate-shaped member before performing laser welding. This pre-prepared hole allows the spherical surface part to be positioned closer to the laser beam path, enabling welding with reduced laser output while maintaining joining strength. The through-hole serves as a preparatory structure that facilitates more efficient energy transfer during the subsequent welding process.
2Strength
If a spherical surface part is welded to an end face of a plate-shaped member using conventional laser welding methods, then the joining strength is achieved, but spatter is generated during welding
Solution Approach 1:
The through-hole formed in advance serves as a containment structure that directs and controls the welding process. By pre-forming this hole, the patent creates a confined space that reduces spatter generation while maintaining effective welding of the spherical surface part to the plate-shaped member.
3Manufacturing precision
If the plate thickness is reduced in the joining part, then the gap space between the spherical surface part and contact end face is reduced, but the structural integrity may be compromised
Solution Approach 1:
The patent applies local quality by creating a joining part with locally reduced plate thickness only at the specific location where the spherical surface part contacts the end face. This localized thinning reduces the gap space to improve welding precision without compromising the overall structural integrity of the plate-shaped member, as other regions maintain their original thickness and strength.
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
The solution reduces laser output and spatter generation, enables the production of gimbal springs with desired thickness and spring characteristics, and simplifies the manufacturing process by eliminating the need for additional joining processes.
Implementation Method 1
a spherical surface part formed in a spherical surface shape and an end face of a plate-shaped member are joined to each other by laser welding
Implementation Method 2
the spherical surface part of the first member and the end part of the second member are joined to each other by laser welding
Implementation Method 3
capable of suppressing generation of a spatter when the spherical surface part is welded
Data Source
AI summary
A welded structure may include a first member having a spherical surface part, and a second member which is formed in a plate shape. A part of an end face of the second member before laser welding is performed is formed to be a contact end face having a contact part with which a part of the spherical surface part is contacted. The second member is formed with a joining part including the contact end face and the joining part is joined to the spherical surface part by laser welding. At least before laser welding is performed, a plate thickness of the joining part is thinner than a plate thickness of a portion of the second member except the joining part and the spherical surface part of the first member and the end part of the second member are joined to each other by laser welding.