Open Curved Waveguide for Efficient Plastic Welding
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Solution Overview
Problem
Existing waveguides for plastic welding are inefficient in terms of manufacturing process and cost, while maintaining energy efficiency, and often require complex designs that pose safety hazards.
Innovation Solution
A curved and one-sidedly open waveguide with a continuously curved concave reflecting surface, adapted to the desired seam contour, which reduces the number of components and material usage, allowing for safer operation and improved energy transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional closed waveguide designs are used, then energy transmission efficiency is maintained, but manufacturing complexity and cost increase
Solution Approach 1:
The patent extracts one reflecting element from the traditional closed waveguide structure, transforming it from a closed two-sided design to an open one-sided design. This extraction simplifies manufacturing by eliminating the need to create and align two precise reflecting surfaces, while the single reflecting surface is optimized to maintain energy transmission efficiency through homogeneous power density distribution.
Solution Approach 2:
The waveguide is segmented into functional zones along its length, with the reflecting surface divided into multiple sections (first reflecting section, second reflecting section, etc.), each with different curvature radii. This segmentation allows optimization of light reflection at different positions while simplifying the overall structure compared to a fully closed design.
2Manufacturing precision
If complex waveguide designs are used, then welding precision is improved, but safety hazards increase
Solution Approach 1:
By removing one reflecting element and opening the waveguide structure, the patent eliminates potential safety hazards associated with enclosed spaces and multiple reflective surfaces that could cause unpredictable light reflections. The open design allows better control and monitoring of the laser path while maintaining welding precision through the optimized single reflecting surface.
Solution Approach 2:
Instead of using a closed structure to contain and control light, the patent inverts the approach by using an open structure where the single reflecting surface actively directs light in a controlled manner. This inversion simplifies safety considerations while maintaining welding precision through deliberate light path design.
3Stability of the object's composition
If more reflecting elements are used, then light distribution homogeneity is improved, but device complexity increases
Solution Approach 1:
The patent applies local quality by dividing the single reflecting surface into multiple sections, each with different curvature radii tailored to specific positional requirements. The first reflecting section has a different curvature than the second reflecting section, allowing optimization of light distribution at different locations along the waveguide while maintaining a simple overall single-surface structure.
Solution Approach 2:
The patent changes the geometric parameters of the reflecting surface along its length, with curvature radius varying from one section to another. This parameter variation achieves homogeneous power density distribution without requiring multiple separate reflecting elements, thereby maintaining structural simplicity while improving light distribution uniformity.
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 waveguide achieves efficient energy transmission with reduced material costs and safer operation, enabling homogeneous power density distribution and tolerance compensation, enhancing the simplicity and effectiveness of plastic welding processes.
Implementation Method 1
a first reflecting element having a reflecting surface by means of which laser light can be reflected
Data Source
AI summary
A curved and one-sidedly open waveguide for plastic welding, especially for laser transmission welding, includes a first reflecting element having a reflecting surface by means of which laser light can be reflected. The reflecting surface defines a receiving end at which laser light from a laser light source, in particular a light guide or a plurality of light guides, is receivable, and an output end at which laser light is directable into a laser light transmitting work piece. The reflecting surface is defined by a curve between the receiving end and the output end so that the reflecting surface of the first reflecting element has a continuously curved concave shape when viewed in cross-section. Further, the first reflecting element is not opposed by a second reflecting element so that the waveguide is open in the direction normal to the reflecting surface.