Profile Corner Welding With In-Place Weld Bead Removal
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Solution Overview
Problem
Existing methods for producing corner joints in plastic and composite materials result in undesirable weld beads on both visible and non-visible surfaces, requiring additional time and effort to remove, and often create rough surfaces that accumulate dirt and are difficult to clean.
Innovation Solution
A method and device that utilize a machining tool, such as a milling cutter, laser, or water jet cutting device, to remove weld beads after the corner joint is welded, maintaining the profile bars' position, allowing for precise removal without repositioning and accommodating various profile geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If weld beads are removed using knives and/or milling cutters on visible surfaces, then the appearance quality is improved, but the manufacturing time and complexity increase
Solution Approach 1:
The patent applies preliminary action by pressing the outer parts of weld beads inwards immediately after welding, before they solidify completely. This preliminary deformation prevents the formation of prominent visible weld beads, eliminating or reducing the need for subsequent removal operations. The pressing action is performed while the material is still pliable, making the process more efficient and effective.
Solution Approach 2:
The patent achieves continuity of useful action by integrating the weld bead pressing operation directly into the welding process sequence. The pressing occurs immediately after welding without interruption, and the welding mirror is reused for both welding and pressing operations. This eliminates idle time between operations and maintains continuous productive action throughout the manufacturing process.
2Manufacturing precision
If weld beads are pressed inwards and reheated to deform them, then the visible appearance is improved, but the process complexity and time increase
Solution Approach 1:
The patent applies universality by designing the welding mirror to serve multiple functions: it acts as both the welding tool for joining profile bars and the pressing tool for deforming weld beads. The same heated mirror is used sequentially for welding, then for pressing and reheating the weld beads. This multi-functionality eliminates the need for separate specialized tools, reducing device complexity while achieving improved visible surface quality.
3Measurement precision
If multiple tool adjustments and repositionings are performed for weld bead removal, then the removal precision is improved, but the setup time increases
Solution Approach 1:
The patent applies preliminary action by pressing weld beads inwards immediately after welding while the profile bars are still in their original position and the welding mirror is already in place. This preliminary deformation occurs before any repositioning or tool changes are needed, achieving the primary corrective action while minimizing setup time and maintaining precision.
Solution Approach 2:
The patent maintains continuity by performing the pressing operation immediately after welding without interrupting the workflow. The welding mirror remains in position, the profile bars remain clamped, and the process flows continuously from welding to pressing. This eliminates the need for repositioning and tool changes, reducing setup time while maintaining precision through the immediate, controlled pressing action.
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 method achieves high-quality corner joints with no visible weld beads, reducing setup time and increasing process reliability by eliminating the need for repositioning and tool recalibration, while maintaining flexibility for different profile geometries.
Implementation Method 1
their connecting surfaces are placed against a welding mirror heated to a predetermined welding temperature
Implementation Method 2
the two profile bars to be joined are then pressed against the welding plate and melted to such an extent that an initial reduction in length of, for example, approximately 2 mm occurs
Implementation Method 3
the connecting surfaces of the two profile bars to be joined are then pressed against the welding plate and melted
Data Source
Figure 1
AI summary
The invention relates to a method and a device for producing a corner joint (10) between two profile bars (1) made of plastic and/or composite materials, the end faces of which are mitered, in which the profile bars (1) to be joined are clamped in the orientation provided for the corner joint (10) and their connecting surfaces are placed against a welding mirror heated to a predetermined welding temperature and pressed against it under a first shortening of length and formation of a weld bead from the material displaced during the shortening, and after removal of the welding mirror, are joined together under pressure and a further, second shortening of length and welded together to form the corner joint.wherein, after welding the corner joint (10), an outer corner area (100) of the corner joint (10) is machined by an associated machining tool (3) while maintaining the positioning of the profile bars (1), and a weld bead that has erupted in the outer corner area (100) is removed.