Laser Welding Clamp with Reflection Blocking Grippers

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Solution Overview

Problem

In welding applications where conductors are positioned in close parallel alignment, the reflection of welding lasers can inadvertently irradiate connected devices due to the narrow interval between terminals, posing a risk of damage.

Innovation Solution

A welding apparatus featuring a clamp with movable grippers and a laser irradiation system that adjusts the point of laser emission to irradiate diagonally, accompanied by a confronting portion and second gripper that block the optical path of reflected lasers, preventing them from reaching adjacent devices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a welding laser is used to weld a terminal and a busbar in a narrow interval, then welding can be performed on conductors positioned closely together, but the reflection laser can irradiate connected devices and cause damage

Engineering Contradiction:

Improvewelding capability in narrow intervalsVSAvoidreflection laser irradiation to connected devices

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a reflection laser blocking member as an intermediary element positioned between the welding laser source and the connected devices. This blocking member specifically intercepts the reflection laser path without interfering with the welding process, thereby protecting connected devices from laser irradiation while maintaining welding capability in narrow intervals

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The blocking member is positioned in advance to prevent the reflection laser from reaching connected devices before the harmful irradiation can occur. The member is strategically placed to intercept the reflection path during the welding process, proactively preventing potential damage to connected devices

Inventive Principle:

Principle #9Preliminary anti-action

2Productivity

If the laser irradiation apparatus emits welding laser in a diagonal direction, then welding can be performed on the third conductor, but the reflection laser path becomes unpredictable and may reach adjacent devices

Engineering Contradiction:

Improvewelding efficiency on third conductorVSAvoidunpredictable reflection laser path to adjacent devices

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The reflection laser blocking member serves as an intermediary that specifically targets and blocks the diagonal reflection laser path. It is positioned to intercept reflection lasers traveling in various directions from the diagonal welding point, preventing them from reaching adjacent devices while allowing the welding process to proceed efficiently

Inventive Principle:

Principle #24Intermediary (Mediator)

3Area of stationary object

If the interval between terminals is narrow, then space utilization is improved, but the risk of reflection laser damaging connected devices increases

Engineering Contradiction:

Improvespace utilization between terminalsVSAvoidreflection laser damage risk to connected devices

Core Design Contradiction:

Area of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The blocking member is strategically positioned in the narrow space between terminals to intercept reflection lasers. It acts as a mediator that protects connected devices without occupying excessive space, allowing the system to maintain narrow terminal intervals for better space utilization while preventing laser damage

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Effectively blocks reflection lasers, ensuring safe and precise welding between conductors at narrow intervals by positioning the confronting portion and second gripper to intercept the optical path of reflected welding lasers, thereby protecting connected devices.

Implementation Method 1

There are instances where a laser (a welding laser) is used to weld a terminal and a busbar to each other

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Implementation Method 2

the confronting portion and the second gripper are positioned so as to block an optical path of a reflection laser of the welding laser reflected within the given range of the third conductor

Methodology Applied

Scientific EffectOptical path blocking: Absorption (EM radiation)

Data Source

PatentUS11198194B2Laser welding apparatus with a clamp

Publication Date: 2021.12.14 DENSO CORP

AI summary

A welding apparatus that welds a third conductor to a first conductor includes a clamp and a laser irradiation apparatus, the third conductor being adjacent to the first conductor between the first conductor and a second conductor extending in parallel to each other. The clamp is configured to sandwich the first conductor and the third conductor between a first gripper and a second gripper. The laser irradiation apparatus is configured to emit a welding laser towards the third conductor. The first gripper includes a confronting portion facing a contact surface that comes into contact with the first conductor. In a state where the clamp sandwiches the first conductor and the third conductor, the confronting portion and the second gripper are positioned so as to block a reflection laser of the welding laser reflected in a given range of the third conductor.