Razor Blade Assembly Keyhole Welding for Stronger Welds
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Solution Overview
Problem
Conduction laser welding in razor blade assemblies results in weaker welds with lower process margins, requires longer weld times, and involves complex control strategies and high maintenance, leading to defects and increased costs.
Innovation Solution
Employing a keyhole welding process that produces a weld with a uniform width and greater depth, reducing heat input and eliminating the need for complex machinery, resulting in stronger and more consistent welds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conduction laser welding is used to join the razor blade to the blade support, then the welding process can be implemented, but the weld area exhibits lower process margins and weaker weld strength
Solution Approach 1:
The patent changes the welding process parameters by transitioning from conduction laser welding to keyhole laser welding. This fundamental parameter change alters the welding mechanism from surface heating with conduction to deep penetration with vapor keyhole formation, resulting in stronger welds with deeper penetration and improved process margins.
2Strength
If the weld area size is increased to obtain a stronger weld with conduction laser welding, then weld strength improves, but weld time increases and heat distortion occurs
Solution Approach 1:
The patent changes the welding mode from conduction to keyhole welding, which fundamentally alters the heat input characteristics. Keyhole welding achieves deeper penetration with shorter weld times and reduced total heat input, eliminating the trade-off between weld strength and weld time that exists in conduction welding.
3Length of stationary object
If longer weld times are used to increase weld depth with conduction laser welding, then weld depth increases, but heat distortion and process variations increase
Solution Approach 1:
The patent transitions to keyhole welding which changes the depth mechanism from time-dependent conduction to direct vapor keyhole penetration. This allows achieving greater weld depths with shorter exposure times and lower total heat input, thereby reducing heat distortion and process variations.
4Reliability
If conduction laser welding is used to ensure good quality and consistent welds, then weld quality can be maintained, but complex control strategy and frequent maintenance are required
Solution Approach 1:
The patent changes the welding process to keyhole welding, which is inherently more tolerant of parameter variations and less sensitive to positioning errors. This simplifies the control strategy requirements while maintaining or improving weld quality consistency, and reduces the frequency of maintenance and inspection needed.
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
Keyhole welding produces welds with enhanced strength and consistency, reducing heat distortion and maintenance needs, while allowing for more efficient and flexible manufacturing.
Implementation Method 1
Conduction laser welding relies on surface heating of a part to create a molten pool of material that grows in width and depth via conduction and convection processes
Implementation Method 2
Conduction laser welding relies on surface heating of a part to create a molten pool of material that grows in width and depth via conduction and convection processes
Implementation Method 3
keyhole welding process for forming a razor blade assembly... The keyhole welding process is faster, requires less heat input, and generates a higher quality and more consistent weld
Data Source
Figure 1
Figure 2~3A
Figure 3B~4
AI summary
A method of joining a razor blade to a blade support to form a razor blade assembly, the method including: directing a laser beam having an adjustable power output at an upper surface of the razor blade; and while advancing the laser beam along the razor blade: a) applying the laser beam at a first power output to the razor blade; b) reducing the first power output of the laser beam to a second power output; and c) applying the laser beam at the second power output to the razor to form a weld area joining the razor blade to the blade support. The weld area may be elongated and may include (i) a ratio of depth:width that is greater than about 2:1, and/or (ii) a ratio of length:width that is greater than about 5:1.