Vehicle Light Laser Welding Light Guide for Uniform Energy Distribution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing simultaneous laser welding techniques for vehicle lights are complex, slow, and expensive due to non-uniform energy distribution across the weld interface, leading to suboptimal weld quality and strength.
Innovation Solution
The use of a simultaneous laser welding equipment with a light guide featuring diffusion elements that expand light beams tangentially along the weld interface, ensuring even energy distribution and improved weld quality, combined with a reduced number of optical fibers and a hybrid system of refractive and reflective diffusion elements to optimize energy delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a bundle of optical fibres with a light guide is used to distribute laser beams across the weld interface, then the laser energy can be delivered to multiple points simultaneously, but the energy distribution remains non-uniform with peaks and minimums that compromise weld quality
Solution Approach 1:
The patent introduces a light guide as an intermediary component between the optical fibres and the weld interface. This light guide redistributes the laser energy uniformly across the entire weld interface, eliminating the non-uniform energy peaks and minimums that would otherwise compromise weld quality while maintaining the productivity benefits of simultaneous multi-point welding.
Solution Approach 2:
The patent modifies the energy distribution parameters by using a light guide to transform the discrete, non-uniform energy peaks from individual optical fibres into a continuous, uniform energy distribution across the weld interface, thereby achieving both high productivity and manufacturing precision.
2Manufacturing precision
If multiple optical fibres are used to achieve uniform energy distribution, then weld quality improves, but the number of optical fibres and equipment complexity increases
Solution Approach 1:
The patent merges multiple optical fibres into a single light guide structure that distributes energy uniformly across the weld interface. This consolidation reduces the number of individual optical fibre components needed while achieving the desired uniform energy distribution and weld quality, thereby reducing equipment complexity.
Solution Approach 2:
The light guide serves multiple functions: it receives laser energy from optical fibres, redistributes it uniformly across the weld interface, and eliminates the need for numerous individual optical fibre arrangements. This multi-functionality reduces overall system complexity while maintaining weld quality.
3Reliability
If traditional laser welding processes are used for lenticular bodies to container bodies, then welding can be performed, but the process is complex, slow and expensive
Solution Approach 1:
The patent employs simultaneous laser welding across the entire weld interface rather than sequential point-by-point welding. This parallel periodic action delivers laser energy uniformly across all points of the weld interface at the same time, dramatically increasing welding speed while maintaining weld strength and reliability.
Solution Approach 2:
The light guide ensures continuous and uniform distribution of laser energy across the entire weld interface throughout the welding process. This continuous energy delivery eliminates interruptions and maintains consistent weld quality, achieving both high productivity and reliability simultaneously.
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 approach enables faster, more cost-effective simultaneous laser welding of vehicle lights with improved weld quality and strength, capable of handling complex geometries, while reducing the number of optical fibers and overall equipment dimensions.
Implementation Method 1
a plurality of optical fibres, each extending from an input end to an output end, associated, at the input ends, to the at least one laser source and suitable to transmit the light beams
Implementation Method 2
The light guide includes diffusion elements that pass through said perimetral contour of the seat of the light guide internally, so as to intercept and influence the light beams that propagate inside said seat. The diffusion elements are shaped to expand the light beams along a direction substantially tangent to the curvilinear abscissa defining the perimetral contour
Implementation Method 3
During the welding step, the container body acts as an absorbing member in relation to the light beam emitted by the laser source while the lenticular body acts as a transmissive member of the light beam. The lenticular body substantially transmits, without absorbing it, the laser beam incident thereon which reaches the weld interface. At this point, the laser beam is absorbed by the perimeter edge of the container body which warms up to softening point
Implementation Method 4
At this point, the laser beam is absorbed by the perimeter edge of the container body which warms up to softening point. The softening, accompanied by a reciprocal pressure of approach between the bodies, determines the partial interpenetration between the profiles and therefore the realization of a weld bead on said weld interface
Data Source
AI summary
Simultaneous laser welding equipment of a vehicle light including at least a plurality of laser sources suitable for emitting light beams, a plurality of optical fibres associated, at the input ends to the at least one laser source and transmitting the light beams. A light guide is provided with at least one hollow seat that delimits a continuous perimetral contour, counter-shaped to the weld interface. The light guide comprises diffusion elements that pass through the perimetral contour of the seat of the light guide internally, so as to intercept and influence the light beams that propagate inside the seat and that are shaped to expand the light beams along a direction substantially tangent to the curvilinear abscissa defining the perimetral contour, before it projects from the light output wall and/or at the latter.