Razor Blade Assembly Keyhole Weld Geometry for Higher Retention Strength
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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
The use of keyhole welding process to create razor blade assemblies with narrower, deeper welds that are uniform in width along their depth, allowing for stronger welds with less heat input and reduced maintenance needs.
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 parameters by transitioning from conduction laser welding to keyhole laser welding, which fundamentally alters the welding mechanism. Keyhole welding creates a deeper, more consistent weld profile with better penetration, directly improving weld strength and process reliability without requiring increased weld area or longer weld times.
2Strength
If the weld area size is increased to obtain a stronger weld, 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 allows achieving stronger welds with shorter weld times. The keyhole mechanism enables deeper penetration and better weld strength without requiring increased weld area or extended welding duration, thus avoiding heat distortion and reducing weld time.
Solution Approach 2:
The patent replaces the conduction-based heating mechanism with a keyhole-based welding mechanism. This substitution fundamentally changes how heat is delivered and utilized, enabling more efficient energy transfer and deeper penetration without requiring longer welding times or increased heat input, thereby resolving the contradiction between weld strength and weld time.
3Ease of manufacture
If conduction laser welding is used, then welding can be performed, but complex control strategy and frequent maintenance are required
Solution Approach 1:
The patent replaces the complex conduction laser welding system with a keyhole laser welding system. This substitution simplifies the control strategy by eliminating the need for complex thermal management and monitoring systems required in conduction welding. The keyhole process is more self-regulating and requires less frequent maintenance, directly reducing device complexity while maintaining ease of manufacture.
4Ease of manufacture
If conduction laser welding is used, then welding can be performed, but heat distortion of the part occurs
Solution Approach 1:
The patent changes the welding mechanism from conduction-based surface heating to keyhole-based deep penetration welding. This parameter change allows for more concentrated and efficient heat utilization, reducing overall heat input and minimizing heat distortion of the razor blade and blade support while maintaining welding capability.
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 stronger, more consistent welds with less heat distortion and lower maintenance requirements, enhancing weld retention strength and reducing production costs.
Implementation Method 1
keyhole welding process to create razor blade assemblies with narrower, deeper welds that are uniform in width along their depth
Implementation Method 2
one or more weld areas joining the razor blade to the blade support
Data Source
AI summary
A razor blade assembly including: a razor blade; a blade support; and one or more weld areas joining the razor blade to the blade support, each weld area having a length and a width, in which the width is about 0.05 mm to about 0.15 mm. Also provided is a razor blade assembly including: a razor blade; a blade support; and one or more weld areas joining the razor blade to the blade support, each weld area including a depth and a width, in which the depth is about 0.10 mm to about 0.20 mm.