Laser Welding of Resin Protrusions for Stronger Plastic Joints
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Solution Overview
Problem
Existing methods for welding synthetic resin members with high laser light absorbency face challenges in achieving strong joints due to incomplete melting and increased complexity with the use of joining materials, leading to reduced welding strength and rigidity.
Innovation Solution
A method involving a protrusion on one member with a laser beam applied to its side surface to melt both the protrusion and the contacting surface of the second member, allowing for enhanced heat transfer and mixing of melted materials without the need for additional joining materials, thereby increasing welding strength and simplifying the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a laser beam is applied to weld synthetic resin members with high laser light absorbency, then welding can be achieved, but incomplete melting occurs leading to reduced welding strength
Solution Approach 1:
The invention introduces a groove structure that divides the welding region into multiple zones, allowing the laser beam to systematically melt different portions of the synthetic resin members. The groove guides the laser beam path ensuring complete melting of the welding surfaces while preventing excessive heat accumulation in any single location.
Solution Approach 2:
The invention applies local quality by creating a groove with specific geometric characteristics (depth, width, angle) at the welding location. This localized structural modification concentrates the laser energy precisely where needed, ensuring complete melting of the high-absorbency synthetic resin members without affecting the overall integrity of the components.
2Strength
If joining materials are used to weld synthetic resin members, then welding can be achieved, but the number of components increases and welding strength is reduced
Solution Approach 1:
The invention extracts and eliminates the joining material from the welding system. Instead of using additional materials to facilitate welding, the method relies on direct laser-induced melting and fusion of the base synthetic resin members themselves, thereby reducing component count while maintaining or improving weld strength.
Solution Approach 2:
The synthetic resin members serve their own welding function by being directly melted and fused together through laser irradiation. The groove structure facilitates this self-welding process by guiding heat distribution and material flow, eliminating the need for external joining materials.
3Strength
If a laser beam is applied to melt synthetic resin material, then welding can be achieved, but heat distribution is uneven leading to inconsistent welding quality
Solution Approach 1:
The invention transitions from surface-level laser heating to three-dimensional heat distribution by introducing a groove structure. The laser beam irradiates the groove walls and bottom, creating uniform heat distribution throughout the welding volume. This volumetric heating approach ensures consistent melting and fusion throughout the joint region.
Solution Approach 2:
The groove structure is pre-formed in the synthetic resin members before welding. This preliminary geometric modification prepares the material to receive and distribute laser energy uniformly during the welding process, ensuring consistent heat distribution and melting quality from the outset.
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 approach enables strong and reliable welding of synthetic resin members with high laser light absorbency by ensuring complete melting and mixing of materials, enhancing the joint strength and reducing the number of components required, while maintaining consistent mechanical properties.
Implementation Method 1
a laser beam is applied to a side surface of the protrusion in a state in which a top surface of the protrusion of the first member is abutted against the second member, so as to melt at least the entire top surface of the protrusion and melt a portion of the second member, which portion is in contact with the top surface
Implementation Method 2
heat of the melted top surface is transmitted to a portion of the second member in contact with the top surface
Implementation Method 3
The melted synthetic resin material spreads between the first member and the second member
Implementation Method 4
The synthetic resin material having spread between the first member and the second member cools to solidify
Data Source
AI summary
A protrusion on a first member made of synthetic resin wherein a laser beam is applied to a side surface of the protrusion in a state in which a top surface of the protrusion of the first member is abutted against a second member made of synthetic resin, so as to melt at least the entire top surface of the protrusion and melt a portion of the second member in contact with the protrusion by heat of the melted top surface of the protrusion, followed by solidification of the melted portions, whereby the first member and the second member are welded together.