Seal Device With Multiple Laser Beams For Stable Welding
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Solution Overview
Problem
Existing sealing devices for welding overlapping film sections using laser-heated heating elements face issues with instability, high energy consumption, and inefficient energy distribution due to the need for extensive heating of the entire element, which complicates handling and increases cycle time.
Innovation Solution
A sealing device with a heating element that uses multiple laser sources to create distributed impact points on the heating element, allowing for precise heating and reducing the need for extensive heating, combined with an electrical resistance heating element to preheat the element to a lower temperature, and a pressure body with reduced thermal conductivity to minimize energy loss and improve stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a single laser beam is used to heat the heating element, then the heating element can be heated, but only a short area around the impact point is significantly heated and extensive heating of the entire element is required
Solution Approach 1:
The heating element is divided into multiple heating zones corresponding to multiple laser impact points distributed across its width. Each laser beam heats a specific segment of the heating element, allowing selective and localized heating rather than requiring the entire element to be heated uniformly.
Solution Approach 2:
Multiple laser beams are combined to simultaneously heat multiple areas of the heating element. The plurality of laser sources work together to distribute thermal energy across different zones of the heating element, achieving comprehensive heating more efficiently than a single laser beam could provide.
2Manufacturing precision
If the heating element is heated over its entire width, then uniform heating is achieved, but the cycle time is extended due to the time required to heat and cool the entire element
Solution Approach 1:
The heating process is segmented into multiple parallel heating zones across the heating element width. Multiple laser beams simultaneously heat different segments, achieving uniform temperature distribution across the entire heating element width without requiring sequential heating, thus reducing the overall heating time and cycle time.
Solution Approach 2:
Multiple laser beams operate simultaneously to heat different zones of the heating element at the same time, maintaining continuous and parallel useful action throughout the heating process. This eliminates the time loss associated with sequential heating of different areas.
3Use of energy by moving object
If the pressure body is made transparent to laser beams, then the laser beams can pass through to heat the heating element, but the structural stability of the pressure body is compromised
Solution Approach 1:
The pressure body is segmented with multiple small openings distributed across its structure, each allowing a specific laser beam to pass through to a corresponding heating zone. This segmented approach maintains structural integrity by preserving most of the pressure body material while providing targeted laser access points.
Solution Approach 2:
The pressure body is designed with localized openings only in the areas where laser beam transmission is required, while maintaining solid structure in other areas for stability. Each opening is positioned precisely to allow laser beams to reach the heating element without compromising the overall structural rigidity of the pressure 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 solution enables efficient and precise welding with reduced energy consumption, improved stability of the pressure body, and enhanced welding quality by limiting unnecessary energy input, thus addressing the limitations of previous technologies.
Implementation Method 1
a heating device which comprises a plurality of laser sources (12) and a heating element (03, 04), with the heating element being capable of absorbing the laser beam (15) to heat it up
Implementation Method 2
the heating element (03, 04) is expanded by an electrical resistance heating element or is itself designed as an electrical resistance heating element
Implementation Method 3
a pressure body with reduced thermal conductivity to minimize energy loss
Data Source
Figure 1
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AI summary
The invention relates to a sealing device for welding two overlapping film sections with a movable welding jaw (01), which (01) comprises at least one heating element (03, 04) arranged on the side facing the film sections on a pressure body (06). The heating element (03, 04) is heated by at least one laser beam (15) emitted from a laser source (12). To improve the stability of the pressure body (06), a plurality of laser beams (15) distributed over the width of the heating element (03, 04) are used.