Laser Welding Clamp Layout for Beam Shading-Free Weld Seams
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Solution Overview
Problem
Conventional clamping apparatuses for laser welding of plastics suffer from limited service life due to laser beam shading by metal bars, leading to non-uniform energy input and complications in process management, which affects the quality of the weld seam.
Innovation Solution
A clamping apparatus with a mirror element arranged near fastening elements to reflect the laser beam around them, ensuring continuous and uniform energy application along the welding contour without altering process parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal bars are used as fastening elements to connect clamping jaws, then structural stability is improved, but laser beam shading occurs leading to limited service life and non-uniform energy input
Solution Approach 1:
A mirror element is introduced as an intermediary component to redirect the laser beam around the metal bar fastening elements. The mirror reflects the laser beam onto the welding contour that would otherwise be shaded by the bars, allowing the metal bars to maintain structural stability without compromising laser beam access or service life
Solution Approach 2:
The patent replaces the direct mechanical path of the laser beam with an optical path using a mirror. Instead of the laser beam traveling directly through the clamping apparatus structure, it is reflected by the mirror element to reach the welding zone, eliminating the shading problem caused by metal fastening bars
2Strength
If metal bars are used as fastening elements, then structural stability is improved, but beam shading requires complicated process management to compensate
Solution Approach 1:
The mirror element serves as a passive optical intermediary that automatically redirects the laser beam around the metal bars. This eliminates the need for active process management or control systems to compensate for beam shading, as the mirror physically guides the beam along the correct path without requiring monitoring or adjustment
Solution Approach 2:
Instead of trying to modify the laser beam parameters or control system to compensate for the shading caused by metal bars, the patent inverts the approach by using a mirror to redirect the beam around the bars. This reverses the problem-solving strategy from active compensation to passive redirection, simplifying the overall system
3Strength
If metal bars are used as fastening elements, then structural stability is improved, but uniform energy input is compromised affecting weld seam quality
Solution Approach 1:
The mirror element acts as an optical intermediary that ensures uniform energy distribution across the welding contour by reflecting the laser beam around the metal bars. This allows the full laser energy to reach all areas of the welding seam without the non-uniform shading effects that would otherwise compromise weld quality
Solution Approach 2:
The mirror element is positioned specifically to address the local shading problem caused by the metal bars. By placing the mirror at the appropriate location, the patent ensures that only the affected areas behind the bars receive redirected laser energy, while other areas continue to receive direct beam energy, achieving uniform overall energy input
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 enables the production of homogeneous and uninterrupted weld seams by deflecting the laser beam with a mirror element, eliminating the need for complex process adjustments and extending the service life of the clamping apparatus.
Implementation Method 1
a mirror element (17) which is arranged such that a laser beam (4) is reflected onto a section of the welding contour (14) concealed by the fastening element (15)
Implementation Method 2
By means of a laser beam, the parts to be joined are melted in the area of the joining surfaces
Implementation Method 3
the lower shaped part is made of a material that absorbs the laser beam
Data Source
AI summary
A clamping apparatus for clamping shaped parts which are welded along a welding contour by irradiation with a laser beam, includes a first clamping plate used as a holder for a first shaped part, a second clamping plate which is designed to apply a clamping force to the first shaped part and a second shaped part arranged thereon, an outer clamping jaw including a recess and an inner clamping jaw arranged in the recess, which together form the second clamping plate, a passage gap for the laser beam formed in sections between the outer clamping jaw and the inner clamping jaw, and one or more fastening elements which connect the outer clamping jaw with the inner clamping jaw in sections and which bridge the passage gap; and further includes a mirror element arranged such that the laser beam is reflected onto a section of the welding contour.