Plastic Cooling Profile Assembly for Laser-Welded Fluid Channels
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Solution Overview
Problem
The production of hollow, strip-shaped basic profiles from plastics material is complex and expensive, and the connection of these profiles to connection units using thermal joining methods like laser welding is challenging due to production engineering issues.
Innovation Solution
The use of an elongate basic profile extruded from plastics material with fluid flow channels separated by webs, combined with a partially transparent connection unit, allows for automated laser welding by guiding the laser beam through transparent portions, and the use of assembly aids or calibration pieces to ensure proper alignment and contact for seamless integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If basic profiles are produced from plastics material using extrusion method, then production costs are reduced and design freedom is increased, but production engineering problems occur that do not occur with metal profiles
Solution Approach 1:
The connection unit is made partially transparent (specifically at the connection surface) while other parts can be opaque. This local transparency enables laser beam passage for welding at the critical connection area without requiring the entire component to be transparent, thus solving the production engineering problem while maintaining cost benefits of plastic extrusion
Solution Approach 2:
The connection unit is produced from a transparent plastics material that allows laser beam passage, while the basic profile is produced from standard plastics material via extrusion. This composite material approach enables automated laser welding of the connection unit to the basic profile, resolving the production engineering challenges of joining plastic components
2Extent of automation
If connection unit is made transparent to allow laser beam passage, then automated laser welding becomes possible, but manufacturing complexity increases
Solution Approach 1:
The connection unit is made partially transparent (specifically at the connection surface) while other parts can be opaque. This local transparency enables laser beam passage for welding at the critical connection area without requiring the entire component to be transparent, thus solving the production engineering problem while maintaining cost benefits of plastic extrusion
Solution Approach 2:
The connection unit is designed as a separate component with a specific transparent connection surface that can be joined to the basic profile. This segmentation allows the transparent connection area to be optimized for laser welding while other parts of the connection unit can be designed for their specific functions without transparency 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
Enables efficient, automated, and cost-effective production of plastic-based temperature control devices with high design freedom and compliance with safety regulations, reducing production costs and ensuring reliable fluid flow.
Implementation Method 1
the laser beam can be guided through the transparent portion of the connection unit and can heat the material of the basic profile, so that the connection unit can be welded to the basic profile
Implementation Method 2
fluid flow channels through which a fluid flows being formed in the interior of these bodies to absorb and dissipate the generated heat
Data Source
AI summary
The present invention relates to a device for controlling the temperature of a component and a method of production thereof. The device includes an elongate basic profile that defines a plurality of fluid flow channels in its interior. The fluid flow channels are arranged in series and separated by webs. The elongate basic profile extrudes from a plastic material. The device includes a connection unit connected to the basic profile and designed to direct fluid into the basic profile or out of the basic profile. The connection unit is formed partially or completely from a transparent plastic material.