Laser Welding Optics Shielding Using Gas Vortex Spatter Blocking
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Solution Overview
Problem
Conventional welding devices face challenges in effectively blocking spatter and fume generated during welding, leading to contamination of protective glass and reduced laser transmittance, resulting in welding defects.
Innovation Solution
A welding device incorporating a laser irradiation module, a protection module, and a blocking module that uses gas to form a vortex and block flying particles, preventing them from reaching the protection module and minimizing contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protective glass is used to prevent contamination from spatter and fume, then the optical components are protected from damage, but the protective glass becomes contaminated by spatter and fume, reducing laser transmittance
Solution Approach 1:
A gas flow field is introduced as an intermediary between the welding zone and the protective glass. The gas flow acts as a mediator that captures and redirects spatter and fume particles away from the protective glass, allowing the glass to maintain its protective function while preventing contamination that would reduce laser transmittance.
Solution Approach 2:
The invention employs gas flow (pneumatics) to control the movement of spatter and fume particles. By directing gas flow in specific patterns, the system creates aerodynamic forces that prevent particles from reaching the protective glass, thereby maintaining optical clarity without compromising the protective function.
2Device complexity
If spatter and fume are allowed to flow freely during welding, then the welding process is simple, but spatter and fume contaminate the protective glass, reducing laser transmittance and causing welding defects
Solution Approach 1:
Gas flow is used to control particle movement during welding. The pneumatic field directs spatter and fume away from the protective glass, maintaining laser transmittance without requiring complex mechanical barriers or frequent maintenance of the optical path.
Solution Approach 2:
The invention changes the physical parameters of the welding environment by introducing controlled gas flow. This modifies the trajectory and deposition behavior of spatter and fume particles, preventing them from adhering to the protective glass and maintaining optimal laser transmission conditions.
3Manufacturing precision
If the protective glass is frequently cleaned or replaced to maintain transmittance, then welding quality is maintained, but production time is lost and productivity decreases
Solution Approach 1:
The gas flow serves as a preventive intermediary that stops spatter and fume from reaching the protective glass in the first place. This eliminates the need for frequent cleaning or replacement operations, maintaining high laser transmittance throughout extended welding periods and thereby preserving productivity.
Solution Approach 2:
The gas flow system performs preliminary protection by deflecting particles away from the protective glass before they can contaminate it. This preventive action avoids the need for subsequent cleaning or maintenance interruptions, ensuring continuous high-quality welding operations.
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 effectively suppresses the flow of flying particles, maintaining laser transmittance and reducing welding defects by creating a gas vortex within the blocking module to prevent contamination of the protection module.
Implementation Method 1
the blocking module may be configured to form a vortex by the gas introduced therein
Data Source
AI summary
Discussed is a welding device capable of minimizing welding defects, a battery manufacturing device and a vehicle manufacturing device including such a welding device are provided. The welding device can include a laser irradiation module configured to irradiate a laser to a welding portion; a protection module disposed outside the laser irradiation module and configured to block flying particles scattered from the welding portion; and a blocking module disposed outside the protection module and configured to block an inflow of the flying particles to the protection module by introducing a gas therein.