Contactless Laser Welding via Pneumatic Sheet Pressing
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Solution Overview
Problem
Existing laser welding techniques require mechanical pressing units to maintain contact between workpieces, which can cause deformation and are limited by linear displacement and low velocity, necessitating a contactless method with fluid pressure for uniform thermal distribution.
Innovation Solution
A fluid pressure system within a laser head, featuring a piston and cylinder unit, generates pressure to bring sheets into contact without mechanical means, allowing for continuous contact and high-velocity displacement along various paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical pressing units are used to maintain contact between workpieces, then contact between sheets is ensured, but deformation occurs and velocity is limited
Solution Approach 1:
The patent replaces mechanical pressing units with a pneumatic system. A flexible membrane is positioned between the laser beam path and the workpieces, and pneumatic pressure is applied to the membrane to press the sheets together. This substitution eliminates the mechanical contact and deformation issues while maintaining reliable sheet contact through fluid pressure control.
Solution Approach 2:
The invention uses pneumatic pressure to actuate the flexible membrane, which in turn applies uniform pressure to bring the sheets into contact. The pneumatic system allows for controlled, uniform pressure distribution across the welding area, avoiding the localized pressure points and deformation associated with mechanical rollers or pressing units.
2Reliability
If mechanical pressing units with linear displacement are used, then contact is maintained, but velocity is low and path flexibility is limited
Solution Approach 1:
By replacing the mechanical pressing unit with a pneumatic-membrane system, the invention removes the constraint of linear displacement. The flexible membrane can conform to curved and complex paths, allowing the laser head to move at high velocities along arbitrary trajectories while maintaining continuous contact between sheets through pneumatic pressure.
3Force
If mechanical pressing units are used, then contact pressure is applied, but the system complexity increases
Solution Approach 1:
The invention extracts the pressing function from complex mechanical units and implements it through a simple flexible membrane actuated by pneumatic pressure. This eliminates the need for motors, gears, and control systems associated with mechanical pressing units, significantly reducing device complexity while maintaining effective contact pressure.
4Reliability
If mechanical rollers are used to press sheets, then contact is ensured, but scratches are left on the surface
Solution Approach 1:
The patent replaces mechanical rollers with a pneumatic-membrane system that applies distributed pressure without physical contact points. The flexible membrane conforms to the sheet surfaces and applies uniform pressure across the entire contact area, eliminating the localized pressure points that cause scratches while ensuring reliable sheet contact for welding.
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 ensures reliable contact and uniform thermal distribution during laser welding, preventing deformation and enabling high-speed, contactless welding of sheets without mechanical interference.
Implementation Method 1
fluid, such as gas, is supplied through a laser head towards the surface of the top sheet of material... movable part is displaced to a balanced position in which fluid pressure in a gap between the bottom of the moving part and the top sheet of material is sufficient to bring the sheets in contact with one another
Implementation Method 2
laser welding two or more sheets of material... laser head centered along a longitudinal axis... end piece removably mounted on the head
Data Source
AI summary
A method for contactless laser welding of a plurality of sheets of material stacked upon one another includes simultaneously delivering a laser beam and a stream of fluid through a laser head and further through an end cap which is removably mounted to the laser head. The end cap is configured with a stationary cylinder, which is coupled to the laser head, and a piston movable relative the cylinder. The piston moves in response to a pressure differential generated by the fluid in chambers above and below the piston. Once the pressure equilibrium is reached between the chambers, the pressure in the chamber below the piston is sufficient to reliably press the sheets of material against one another during a laser welding operation.