Laser Welding Clamp Structure With Mirror-Redirected Beam Access
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Solution Overview
Problem
Conventional clamping devices for laser welding of plastics suffer from shadowing by metal ridges, leading to uneven energy input and limited service life, making it difficult to produce a continuous and tight weld seam.
Innovation Solution
Incorporating a mirror element in the clamping device to deflect the laser beam around fastening elements, ensuring uninterrupted energy delivery along the welding contour without requiring complex process control adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional clamping devices use metal ridges to connect clamping plates, then structural strength is improved, but laser beam shadowing occurs causing uneven energy input and limited service life
Solution Approach 1:
A mirror element is introduced as an intermediary component to redirect the laser beam around the metal ridges. The mirror element receives the laser beam and reflects it onto the workpiece surface, allowing the beam to bypass the shadowing areas created by the structural ridges while maintaining effective welding energy delivery
Solution Approach 2:
The solution adds a spatial dimension to laser beam delivery by using the mirror element to change the beam's path. Instead of the beam traveling in a straight line and being blocked by ridges, the mirror redirects it at an angle, effectively navigating around the obstacle in three-dimensional space
2Stability of the object's composition
If metal ridges are used to bridge passage gaps in clamping devices, then structural stability is improved, but continuous weld seam quality deteriorates due to shadowing
Solution Approach 1:
The mirror element serves as a mediating optical component that enables the laser beam to reach the weld area without being blocked by the structural ridges. This maintains both the structural integrity of the clamping device and the quality of the weld seam by decoupling the structural support function from the laser beam path
3Device complexity
If fastening elements directly connect clamping jaws, then device simplicity is improved, but laser beam accessibility deteriorates due to shadowing
Solution Approach 1:
The mirror element is integrated into the existing fastening structure, adding minimal complexity while solving the shadowing problem. The mirror is positioned on or near the fastening elements to redirect the beam, maintaining structural simplicity while improving laser accessibility
Solution Approach 2:
By using the mirror to redirect the laser beam at an angle, the solution navigates around the fastening elements in three-dimensional space, allowing the beam to access the weld area without requiring a complete redesign of the fastening structure
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
Enables the production of a homogeneous and continuous weld seam with minimal impact on process parameters, extending the service life of the clamping device and ensuring consistent weld quality.
Implementation Method 1
In the area of a fastening element (15) there is arranged a mirror element (17) in such a way that a laser beam (4) is reflected onto a section of the welding contour (14) which is covered by the fastening element (15)
Implementation Method 2
The parts to be joined are melted in the area of the joining surfaces by means of a laser beam
Implementation Method 3
the lower molded part consists of a material that absorbs the laser beam
Data Source
Figure 1~2
Figure 3~4
AI summary
A clamping apparatus (5) for clamping at least two shaped parts (6, 9) which can be welded along a welding contour (14) by irradiation with a laser beam (4), comprising: - a first clamping plate (7) used as a holder for a first shaped part, - a second clamping plate (8) which is designed to apply a clamping force to the first shaped part (6) and a second shaped part (9) arranged thereon, - an outer clamping jaw (11) comprising a recess and an inner clamping jaw (12) arranged in the recess, which together form the second clamping plate (8), - a passage gap (13) for a laser beam (4) formed in sections between the outer clamping jaw (11) and the inner clamping jaw (12), - one or more fastening elements (15) which connect the outer clamping jaw (11) with the inner clamping jaw (12) in sections and which bridge the passage gap (13), wherein the clamping apparatus (5) comprises, in the region of a fastening element (15), a mirror element (17) which is arranged such that a laser beam (4) is reflected onto a section of the weld contour (14) concealed by the fastening element (15).