Resin Connector End Structure for Stable Laser Tube Welding
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Solution Overview
Problem
The existing resin connector connection structures face variations in joining strength due to the presence of fillers, which affect the transmittance of laser beams and subsequently the welding quality between resin connectors and tubes, leading to inconsistent bending elastic modulus and joining strength.
Innovation Solution
A resin connector connection structure is designed with a tubular shape, featuring a connector main body with a reinforcing filler for high bending elastic modulus and a connector end portion without or with a lower proportion of filler for higher laser beam transmittance, allowing for differentiated functions to ensure consistent joining strength and bending elastic modulus. The method involves welding the resin tube to the connector end portion using a laser beam, which has a higher absorption rate than the connector end portion, at a position other than the axial position of the connector main body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a resin connector contains reinforcing filler to increase bending elastic modulus, then the bending elastic modulus is improved, but the transmittance of laser beam deteriorates causing variation in joining strength
Solution Approach 1:
The resin connector is divided into two distinct portions: a main body portion containing reinforcing filler for high bending elastic modulus, and an end portion free of filler or with lower filler content for high laser beam transmittance. This segmentation allows each portion to optimize its material composition for its specific function, resolving the contradiction between structural strength and welding consistency.
Solution Approach 2:
Different regions of the resin connector are assigned different material properties: the main body portion has high filler content for structural rigidity, while the end portion has low or no filler for optimal laser beam transmission. This local differentiation of material quality enables simultaneous achievement of high bending elastic modulus and consistent joining strength.
2Strength
If the resin tube is welded to the connector main body portion, then the joining strength can be maximized, but the variation in joining strength increases due to filler interference with laser beam
Solution Approach 1:
The reinforcing filler is extracted or removed from the end portion of the connector that undergoes laser welding with the resin tube. This extraction eliminates the harmful interference of filler particles with laser beam transmission during the welding process, ensuring uniform heat distribution and consistent joining strength without compromising the overall structural integrity provided by the filler in the main body.
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 configuration ensures a consistent bending elastic modulus of the resin connector while minimizing variations in joining strength between the connector and tube, enhancing the overall connection reliability and sealing performance.
Implementation Method 1
welding using a laser beam described in Patent Literature 1
Implementation Method 2
heat energy generated at the welded portion varies due to an influence of the filler
Implementation Method 3
the resin tube is formed of a material having a higher absorption rate of a laser beam than the connector end portion
Data Source
AI summary
A resin connector (10) includes a tubular connector main body portion (11) which is formed to contain a reinforcing filler in a main portion base material resin, and a tubular connector end portion (12) which is formed of a end portion base material resin without containing the reinforcing filler or containing the reinforcing filler at a lower proportion than the connector main body portion (11) and is joined to the connector main body portion (11) to constitute a tubular end portion. The resin tube (20) is formed of a material having a higher absorption rate of a laser beam than the connector end portion (12) and is fitted to the connector end portion (12) to be welded to an inner peripheral surface or an outer peripheral surface of the connector end portion (12) and not to be welded to the connector main body portion (11).