T-Shaped Ceiling Profile Welding for Low-Deformation Rigidity
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Solution Overview
Problem
Existing methods for manufacturing profile members for suspended ceiling systems face challenges in achieving high mechanical strength and rigidity while minimizing weight, and they often suffer from thermal-induced deformation during laser welding processes.
Innovation Solution
A method involving laser welding with alternating energy levels to join the web side walls of T-shaped profile members, allowing for adjustable torsional stiffness and reduced thermal load, thereby minimizing deformation and enhancing dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If continuous laser welding at high energy level is used to join web side walls, then welding strength is improved, but thermal-induced deformation increases
Solution Approach 1:
The patent applies periodic action by alternating between high energy level welding and low energy level welding in a cyclic pattern along the weld joint. This periodic variation in energy input allows the material to undergo controlled thermal cycles that promote weld strength while minimizing cumulative thermal distortion, thereby resolving the contradiction between welding strength and dimensional accuracy.
Solution Approach 2:
The patent changes the energy level parameter during the welding process by switching between at least two different energy levels. This dynamic parameter adjustment allows optimization of both weld penetration (at high energy) and thermal distortion control (at low energy), simultaneously achieving high welding strength and maintained dimensional accuracy.
2Productivity
If laser welding is performed at high production speed, then productivity is improved, but thermal-induced deformation increases
Solution Approach 1:
By implementing periodic alternation between high and low energy levels synchronized with the production speed, the method maintains high overall welding speed while periodically reducing thermal input to prevent distortion. This allows high productivity to be achieved without sacrificing dimensional accuracy.
3Weight of moving object
If thinner sheet metal material is used to reduce weight, then weight is reduced, but mechanical strength decreases
Solution Approach 1:
By changing the energy level parameters during welding, the method achieves superior weld penetration and strength in thinner materials. The alternating high-energy phases provide sufficient heat input for strong welds in thin gauge material, while low-energy phases prevent burn-through and distortion, enabling use of thinner, lighter material without compromising mechanical strength.
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
The method results in profile members with improved strength, rigidity, and reduced thermal deformation, enabling higher production rates and cost-effectiveness by allowing for thinner materials and easier handling, while maintaining high dimensional accuracy in the grid of profiles.
Implementation Method 1
improve its strength and rigidity by laser welding the two web side walls to each other
Implementation Method 2
The step of laser welding comprises alternatingly performing a first operation and a second operation... whereby thermal-induced deformation of the profile member is minimized
Data Source
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AI summary
A method for manufacturing a profile member (1) for a suspended ceiling system, comprising forming a sheet metal material into an elongate T-shaped profile member (1) with a web (2) having two web side walls (7a, 7b) and a pair of oppositely disposed flanges (3) projecting from a bottom portion (4) of the web (2), and laser welding the elongate T-shaped profile member (1) for providing a laser weld joint (8) extending in a longitudinal direction (L1) of the T-shaped profile member (1) and joining the two web side walls (7a, 7b) to each other. The step of laser welding comprises alternatingly performing a first operation and a second operation, the second operation being different from the first operation, whereby a laser weld joint (8) is provided comprising along its extension alternating welded first sections (11) associated to the first operation and second sections (12) associated to the second operation. The present invention also relates to an elongate profile member provided with a laser weld joint (8).