Laser Welding Window for Electrical Contact Elements
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Solution Overview
Problem
In mass production of electrical contact elements, establishing a reliable and cost-effective electrical and mechanical connection between two metallic workpieces can be complex and expensive, especially when the geometry of the parts prevents direct lateral irradiation for laser welding.
Innovation Solution
A semi-finished product design featuring a metallic first workpiece with a window that allows laser welding by creating a light trap between the workpieces, enabling absorption and reflection of laser light to melt and join the parts, even in complex geometries, thereby eliminating the need for coatings and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional joining methods are used for complex geometries, then connection reliability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces traditional mechanical joining methods (screws, clips, adhesives) with laser welding technology. The laser beam melts and fuses the workpieces directly, eliminating the need for additional mechanical components or chemical adhesives. This substitution simplifies the manufacturing process while maintaining connection reliability, as the laser welding creates a direct metallurgical bond between the workpieces.
Solution Approach 2:
The patent utilizes the ability to precisely control laser welding parameters (power, speed, focal position) to adapt to complex geometries. By adjusting these parameters, the process can accommodate varying workpiece shapes, thicknesses, and materials without requiring different joining mechanisms, thereby maintaining reliability while reducing manufacturing complexity.
2Ease of manufacture
If lateral irradiation is used for laser welding, then process simplicity is improved, but applicability to complex geometries deteriorates
Solution Approach 1:
The patent transitions from lateral irradiation (side approach) to end irradiation (front approach) of the laser beam. By directing the laser beam from the front side through the window into the cavity, the process can access workpiece surfaces that are geometrically inaccessible from the side, thereby maintaining simplicity while expanding applicability to complex geometries.
Solution Approach 2:
The window structure acts as an intermediary element that enables laser beam access to the cavity interior. It provides a controlled opening through which the laser can reach the workpiece surfaces for welding, facilitating the joining process in geometries where direct lateral access is blocked by the workpiece structure itself.
3Reliability
If coatings are applied to workpieces, then weldability is improved, but manufacturing steps and cost increase
Solution Approach 1:
The patent employs workpiece materials with inherently suitable surface properties for laser welding. By selecting materials that naturally exhibit good laser absorption and weldability without requiring additional surface treatments, the process eliminates the coating application step entirely. The workpiece materials themselves provide the necessary characteristics for successful welding, making the process more efficient and cost-effective.
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 allows for quick, efficient, and cost-effective joining of metallic workpieces, ensuring a permanent electrically conductive and mechanical connection without the need for additional coatings, suitable for various metallic materials, including those difficult to join mechanically.
Implementation Method 1
The surface of the second workpiece, which is accessible through the window, can act as a reflection surface for the laser beam. The laser beam can be reflected at this surface onto the rear side of the first workpiece.
Implementation Method 2
Both materials can be heated by the laser beam so that a welded connection can be created between the two workpieces.
Data Source
AI summary
A semi-finished product for manufacturing an electrical contact element includes a first workpiece having a front side and a rear side opposite the front side, a second workpiece, and a window extending through the first workpiece. The first workpiece and the second workpiece are both metallic. The rear side of the first workpiece is closer to the second workpiece than the front side. Through the window, a surface of the second workpiece is accessible from the first workpiece. The window has a base area that, starting at the front side of the first workpiece, increases toward the second workpiece.