Laser Beam Welding Lamp Housing Using Blocking Ring
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Solution Overview
Problem
Conventional laser-beam welding of lamp components often results in burns and reduced welding strength due to heat accumulation in exposed areas of the flange portion, damaging the external appearance and quality of the lamp.
Innovation Solution
A laser-beam welding method and apparatus that uses a support jig and a laser beam blocking ring to ensure the laser beam is only emitted to the abutment portion, preventing heat from being applied to exposed areas of the flange portion, thereby avoiding burns and maintaining the integrity of the resin surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the flange portion is made larger than the lens leg portion to prevent lens chipping, then the lens protection is improved, but the laser beam may be emitted to exposed portions of the flange portion causing burns and reducing welding strength
Solution Approach 1:
A laser beam blocking ring is introduced as an intermediary component between the laser beam emitting unit and the flange portion. This blocking ring selectively blocks the laser beam from reaching exposed portions of the flange portion while allowing the beam to reach the abutment portion where welding is required, thereby preventing burns without compromising welding strength
Solution Approach 2:
The flange portion surface is segmented into two functional zones: the abutment portion (where welding occurs) and the exposed portion (where lens chipping prevention is needed). The laser beam blocking ring creates a spatial segmentation that directs the laser beam only to the abutment portion, separating the welding function from the structural support function
2Productivity
If the laser beam is emitted to the exposed portion of the flange portion, then the welding process covers the entire flange area, but heat accumulation causes burns and damages the resin surface quality
Solution Approach 1:
The laser beam blocking ring acts as a mediator that modifies the laser beam path, allowing efficient welding at the abutment portion while preventing harmful heat accumulation at the exposed portion, thus maintaining both productivity and surface quality
3Object-affected harmful factors
If the laser beam emitting position is controlled with high accuracy to avoid exposed portions, then burns are prevented, but the complexity of the welding apparatus increases
Solution Approach 1:
Instead of relying on complex control systems to precisely position the laser beam, a simple laser beam blocking ring is introduced as a passive intermediary component. This mechanical solution is far simpler than active control systems while effectively preventing burns by blocking the laser beam from exposed portions
Solution Approach 2:
The laser beam blocking ring is a simple, inexpensive component that can be easily manufactured and replaced if needed, providing a cost-effective solution compared to complex control systems with sensors, actuators, and control algorithms
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 prevents burns and enhances the welding strength and external appearance of the lamp by ensuring the laser beam is confined to the abutment area, improving the reliability of the laser-beam welding process.
Implementation Method 1
a laser beam LB is transmitted through the lens 2 so as to be emitted to a surfaces abutment portion S made up of the abutment surfaces of the two components. The flange portion 11 is heated through the emission of the laser beam LB.
Implementation Method 2
The heat generated is transmitted to the lens leg portion 21 via the surfaces abutment portion S, whereby the flange portion 11 and the lens leg portion 21 are each fused at the surfaces abutment portion S
Implementation Method 3
the emission of the laser beam is blocked so that the laser beam is not emitted to at least any other areas of the opening edge portion than the surfaces abutment portion
Data Source
AI summary
In a lamp including a lamp housing and a lamp cover, the lamp cover is laser-beam welded to an opening edge portion of the lamp housing. There exists no trace of fusion on the opening edge portion of the lamp housing in any other areas than a surfaces abutment portion where the lamp cover is brought into abutment. A method for fabricating a lamp includes bringing a lamp cover into abutment with an opening edge portion of a lamp housing; and emitting a laser beam to a surfaces abutment portion of the lamp housing with the lamp cover so as to laser-beam weld the lamp housing and the lamp cover together. The emission of the laser beam is implemented while blocking the laser beam so that the laser beam is not emitted to at least any other areas of the opening edge portion than the surfaces abutment portion. An apparatus for fabricating a lamp includes support means for rotatably supporting a lamp housing and a lamp cover that is brought into abutment with an opening edge portion of the lamp housing in an abutment state; laser beam emitting means for emitting a laser beam to a surfaces abutment portion of the opening edge portion where the lamp housing is in abutment with the lamp cover; and laser beam blocking means for blocking the emission of a laser beam to at least any other areas of the opening edge portion than the surfaces abutment portion.