Laser Welding Automotive Light Complex Geometries
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Solution Overview
Problem
Existing laser welding techniques are inefficient for automotive lights with complex geometries, resulting in non-uniform irradiation and poor weld quality, leading to the use of alternative welding methods.
Innovation Solution
A method of laser welding that involves directing laser beams with adjustable divergence and orientation to match the curvilinear welding interface, using a plurality of optical fibers and negative light guides to ensure uniform irradiation across complex surfaces, including areas with discontinuities, by adjusting the angle of incidence to optimize beam delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional laser welding techniques are used on automotive lights with complex geometries, then the welding process is simpler and faster, but the irradiation becomes non-uniform and weld quality deteriorates
Solution Approach 1:
The patent divides the single laser beam into multiple separate beams using a beam splitter, with each beam directed to a different welding zone. This segmentation allows uniform irradiation across complex geometries by treating each zone independently, resolving the contradiction between welding speed and quality.
Solution Approach 2:
The patent introduces multiple spatial dimensions for beam delivery by positioning beam splitters and mirrors at different locations and angles. This multi-dimensional approach enables simultaneous irradiation of complex surfaces from multiple directions, maintaining both high productivity and weld quality.
2Device complexity
If the laser beam is directed at complex geometries with conventional methods, then the setup is simpler, but the irradiation distribution becomes non-uniform
Solution Approach 1:
The patent applies local quality by directing specific laser beams to specific welding zones based on their geometric characteristics. Each beam is optimized for its target area, ensuring uniform irradiation distribution across the entire complex geometry while maintaining manageable system complexity.
Solution Approach 2:
The patent introduces beam splitters and mirrors as intermediary components that facilitate precise beam distribution. These intermediaries enable complex irradiation patterns without requiring direct complex positioning of the laser source, thus maintaining system simplicity while achieving uniform irradiation.
3Manufacturing precision
If alternative welding methods are used instead of laser welding for complex geometries, then weld quality improves, but manufacturing cost and time increase
Solution Approach 1:
The patent replaces complex mechanical welding systems with a sophisticated laser beam delivery system. By using multiple laser beams with precise optical control, the system achieves weld quality comparable to alternative methods while maintaining the speed and efficiency advantages of laser welding, thus reducing both cost and time.
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
This method achieves a high-quality weld with complex geometries, reducing costs and time while maintaining excellent mechanical properties of the weld joint, and efficiently utilizing laser radiation without waste.
Implementation Method 1
The container body acts as an absorbing element towards the light beam and the lenticular body acts as a transmissive element of the light beam
Implementation Method 2
at least a laser source, which can for example be a semiconductor laser source
Implementation Method 3
the laser radiation is transformed into heat when it encounters the absorbent polymeric body which heating locally transfers heat to the transmissive polymeric body
Implementation Method 4
a system of optical fibres grouped together in a 'bundle' which serves to transport the laser light produced by the laser source
Implementation Method 5
a negative light guide is used, i.e. a light guide formed of reflective walls inclined with respect to the optical axis of the fibre
Implementation Method 6
an optical system, with the function of a collimator, which has the purpose of modifying the divergence of the laser beam coming out of the fibre
Data Source
AI summary
Method of manufacture of an automotive light comprising the steps of providing a container body delimited by a first perimetral profile, providing a lenticular body, internally delimited by a second perimetral profile and externally by an outer edge corresponding to said second perimetral profile, wherein the container body acts as an absorbent element of the light beam and the lenticular body acts as a transmission element of the light beam, providing optical devices for changing the divergence of the portions of laser beams in output from the fibers, so as to collimate them overall along at least one predetermined optical axis. The method further comprises the steps of directing on a critical portion of the welding interface at least a first laser beam emitted by a respective fiber lying on an optical plane incident with said critical portion of the welding interface.