Laser Welding Wire Mesh Spot Contacts
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Solution Overview
Problem
Existing methods for welding wire-shaped parts with point or short line contact, such as those in wire-mesh structures, are inefficient due to high costs associated with custom-made welding devices and the inability of laser welding to produce high-quality connections without significant air gaps.
Innovation Solution
The method employs a laser welding technique where the laser beam is directed through the top part to focus on the crossing point, melting the material internally while applying slight pre-tension to the parts, which increases the contact area and quality of the weld, and additional side welds are made to enhance strength, using a device that adapts to the product's shape rather than the welding equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If resistance or capacitor discharge welding is used for wire-shaped parts with point or short line contact, then high-quality welds can be achieved, but the device complexity and production costs increase significantly due to type-specific welding devices
Solution Approach 1:
The patent applies universality by using a single laser welding device that can weld wire-shaped parts with various geometries and configurations. The laser beam can be directed through different paths (from above or from the side) and adjusted to accommodate point contacts, short line contacts, and various wire arrangements, eliminating the need for multiple type-specific welding devices required by resistance or capacitor discharge methods.
Solution Approach 2:
The patent replaces the complex mechanical electrode systems of resistance or capacitor discharge welding with a laser beam-based thermal system. Instead of requiring adaptive electrodes and complex clamping mechanisms, the invention uses a laser beam that can be precisely directed and focused to melt and join wire-shaped parts through their material, significantly simplifying the overall welding device structure.
2Device complexity
If laser welding is used for wire-shaped parts with point or short line contact, then device complexity is reduced, but the welding quality deteriorates due to air gaps preventing effective laser beam action
Solution Approach 1:
The patent applies dimensionality change by directing the laser beam through the wire-shaped part itself (from above through the top part) or from the side, rather than attempting to bridge the air gap between parts. This approach uses the third dimension (beam direction) to bypass the air gap problem, allowing the laser energy to reach the contact zone effectively and create high-quality welds despite the presence of air gaps.
Solution Approach 2:
The patent uses the wire-shaped part itself as an intermediary medium. By directing the laser beam through the top part to reach the crossing point, the part acts as a conduit for the laser energy, allowing the beam to deliver heat to the joint zone without being blocked by air gaps. This intermediary approach enables effective energy transfer despite the discontinuous contact between parts.
3Strength
If high surge current energy is supplied via capacitor discharge welding, then weld strength is achieved, but energy consumption and production costs increase
Solution Approach 1:
The patent replaces the high-energy electrical discharge system with a more energy-efficient laser thermal system. The laser beam delivers concentrated thermal energy directly to the weld zone, melting and joining the wire-shaped parts with significantly lower overall energy consumption compared to the high surge currents required by capacitor discharge welding, while achieving equivalent or superior weld strength.
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 reduces production costs and time by allowing for flexible adaptation of the device to various geometries, achieving strong and high-quality welds with reduced repositioning forces and increased connection strength.
Implementation Method 1
A laser beam is directed through the top part to the crossing point and melts the material at the focal point
Implementation Method 2
the laser beam only melts the materials in the boundary zone if there is no appreciable air gap between the parts
Implementation Method 3
As a result of the contact pressure, the thickness of the wires lying on top of one another decreases when the material melts, so that an intimate, planar connection is created between the wires
Implementation Method 4
The repositioning forces must be maintained until the material in the joint has solidified
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a method and a device for welding parts. e.g. wire-shaped parts, with spot-contact or short line contact in the joining region. Said parts are welded by means of a laser beam (10), the parts (2, 3, 6) being aligned relative each other, the laser beam (10) being introduced into the upper part (2) from above and in a centered manner relative to the joining position (7) and fusing only the inner region immediately above the joining position (7) while the upper and the lower part (2, 3, 6) are being pressed against each other such that they move towards each other, the fused region of the upper part (2) penetrating the meanwhile likewise fused material of the respective lower part (3, 6).