Fixed Multi-Surface Reflector for Uniform Tubular Laser Welding
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Solution Overview
Problem
Current laser-welding methods for tubular components in medication delivery devices require complex and error-prone adjustments of optical reflectors to achieve uniform heating, leading to prolonged setup times and inconsistent weld quality in high-production settings.
Innovation Solution
A single, fixed optical reflector with multiple angled reflecting surfaces is used, allowing only vertical adjustment of the workpiece relative to the reflector, eliminating the need for lateral and angular adjustments, and enabling a 'set it and forget it' configuration for consistent 360-degree circumferential welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple adjustable optical reflectors are used to achieve uniform heating coverage, then the heating uniformity can be improved, but the setup time and operational complexity increase significantly
Solution Approach 1:
The patent combines multiple separate optical reflectors into a single integrated reflector structure with multiple reflecting surfaces. This single reflector performs the function of multiple reflectors simultaneously, eliminating the need for individual adjustment of each reflector while maintaining uniform heating coverage across the workpiece.
Solution Approach 2:
The optical reflector is pre-configured with specific geometric angles and surface orientations during manufacturing. This preliminary configuration ensures that the reflector automatically provides uniform heating coverage when positioned correctly, eliminating the need for time-consuming field adjustments of multiple reflectors.
2Area of stationary object
If multiple adjustable optical reflectors are used to redirect the laser beam, then the beam coverage can be improved, but the device complexity and maintenance difficulty increase
Solution Approach 1:
The patent integrates multiple reflecting surfaces into a single optical reflector component. This unified structure provides comprehensive beam coverage while reducing the number of separate optical components from multiple reflectors to just one, thereby simplifying the overall optical system.
Solution Approach 2:
The single optical reflector performs multiple functions simultaneously by redirecting the laser beam to different areas of the workpiece through its multiple reflecting surfaces. This multi-functional design replaces what would otherwise require several separate reflectors, reducing system complexity while maintaining comprehensive coverage.
3Manufacturing precision
If adjustable optical reflectors are used to cover both sides of the workpiece, then the welding coverage can be improved, but the adjustment precision requirements and operational difficulty increase
Solution Approach 1:
The patent combines multiple adjustment mechanisms into a single fixed optical reflector structure. By eliminating the need for separate angular and lateral adjustments of multiple reflectors, the system achieves consistent weld quality while dramatically simplifying the alignment process to a single positioning operation.
Solution Approach 2:
The optical reflector is pre-engineered with fixed geometric configurations that automatically provide the correct beam angles and positions for uniform welding coverage. This preliminary design eliminates the need for operators to perform complex iterative adjustments during setup, reducing both alignment difficulty and precision requirements.
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 significantly reduces setup time and effort while ensuring high-quality, consistent welds across parts, increasing throughput with minimal variability and no need for iterative adjustments.
Implementation Method 1
a single, fixed optical reflector having multiple optically reflecting surfaces
Data Source
AI summary
Device and method for laser welding around a circumference of a workpiece. A fixed, non-movable unitary optical reflector is provided, which has a pair of optical reflecting surface portions on a first side surface and a second side surface, respectively, arranged at an obtuse angle relative to each other. A workpiece is positioned and fixed in an assembly that includes the unitary optical reflector. During setup, the vertical distance is adjusted between the unitary optical reflector and the workpiece along an axis that is transverse to a longitudinal axis of the workpiece without any adjustment of the reflecting surfaces, which remain fixed during setup. The first and second side surfaces define a curve that is transverse to the longitudinal axis. Once setup has been completed, a laser beam is directed so that it moves along the optical reflector to thereby produce a 360 degree circumferential weld around the workpiece.