Rotating Laser Bonding for Full-Circumference Resin Pipe Joints
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Solution Overview
Problem
Existing laser bonding methods for resin members are costly and lack versatility, requiring large, shape-specific devices to join resin pipes and members of various sizes and shapes, limiting their application.
Innovation Solution
A laser bonding method and device that fixes resin pipes and members to a base, using a light emission unit attached to a pulley or gear to revolve around the junction, applying laser light through a reflecting mirror, allowing for easy joining of resin pipes and members with various shapes and sizes without the need for expensive, shape-specific devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large reflecting surface direction changer is provided to surround the junction and reflect laser light, then laser welding over the entire circumference can be achieved, but manufacturing cost increases significantly
Solution Approach 1:
The patent employs a dynamic light emission unit that rotates around the junction rather than using a static large reflecting surface. This dynamic approach allows a compact light source to achieve full circumferential coverage by changing its position and orientation during operation, thereby avoiding the need for an expensive large-scale static reflecting structure while maintaining reliable laser welding quality
Solution Approach 2:
The patent introduces a rotating mirror as an intermediary component that redirects laser light from the light emission unit to the junction. This intermediary mechanism enables the compact light source to effectively cover the entire circumferential area by reflecting light at different angles during rotation, achieving the same effect as a large reflecting surface but with much lower manufacturing cost
2Reliability
If a direction changer with specific shape and size is manufactured for each resin member, then laser welding can be achieved, but versatility is reduced
Solution Approach 1:
The patent designs a universal light emission unit that can handle resin members of various shapes and sizes through rotation. Instead of manufacturing dedicated direction changers for each specific component, this single multi-functional unit adapts to different geometries by changing its rotational parameters and light emission angles, thereby maintaining laser welding capability across diverse applications while significantly improving versatility
Solution Approach 2:
The system uses dynamic rotation and adjustable light emission angles to adapt to different resin member geometries. The light emission unit's ability to rotate and change its effective working position allows it to accommodate various shapes and sizes without requiring custom-manufactured direction changers for each case, thus preserving both welding reliability and broad adaptability
3Adaptability or versatility
If the light emission unit revolves around the junction, then various shapes and sizes can be joined without manufacturing new devices, but device complexity increases
Solution Approach 1:
The patent combines the light emission unit with the rotation mechanism into an integrated assembly. By merging these functions into a single unified structure that rotates as one unit, the system achieves versatility for joining various shapes and sizes while avoiding the complexity of separate independent mechanisms. The combined design simplifies the overall device architecture compared to having separate positioning and light emission systems
Solution Approach 2:
The system uses a simple rotational motion to achieve complex positioning requirements for various resin member geometries. This single degree of freedom (rotation) is sufficient to bring the light emission unit into the correct position for welding different shapes and sizes, avoiding the need for complex multi-axis positioning systems while maintaining high adaptability
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
Enables efficient and cost-effective laser welding of resin pipes and members with various shapes and sizes, ensuring consistent welding temperature and strength by controlling the revolution speed of the light emission unit, reducing manufacturing costs and device complexity.
Implementation Method 1
laser welding over the entire circumference of the junction is achieved
Implementation Method 2
fusing and joining the entire outer circumferential surface of the pipe with the entire inner circumferential surface of the member by applying the laser light
Implementation Method 3
the laser light is applied from the light emission unit to the junction through a reflecting mirror which is configured to revolve around the junction in sync with the light emission unit
Implementation Method 4
inner circumferential surface of a member made of a resin material transmitting laser light
Implementation Method 5
outer circumferential surface of a pipe made of a resin material absorbing laser light
Data Source
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AI summary
A resin pipe 30 and a resin member 31 are fixed to a setting portion 5 provided on the front side of a base 6, and a timing pulley 13 which is provided on the back side of the base 6 and to which a light emission unit 3 is attached is rotated. As a result, the light emission unit 3 applies laser light 20 to a junction 32 between the resin pipe 30 and the resin member 31 while revolving around the junction 32. This makes it easy to fuse and join the entire outer circumferential surface of the resin pipe 30 with the entire inner circumferential surface of the resin member 31, which are variously shaped and sized.