US20150273808A1 - System and method for direct infrared (ir) laser welding - Google Patents
System and method for direct infrared (ir) laser welding Download PDFInfo
- Publication number
- US20150273808A1 US20150273808A1 US14/228,347 US201414228347A US2015273808A1 US 20150273808 A1 US20150273808 A1 US 20150273808A1 US 201414228347 A US201414228347 A US 201414228347A US 2015273808 A1 US2015273808 A1 US 2015273808A1
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- laser beam
- plastic components
- laser
- recited
- joining surfaces
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
- B29C65/16—Laser beams
- B29C65/1603—Laser beams characterised by the type of electromagnetic radiation
- B29C65/1612—Infrared [IR] radiation, e.g. by infrared lasers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
- B29C65/16—Laser beams
- B29C65/1629—Laser beams characterised by the way of heating the interface
- B29C65/1632—Laser beams characterised by the way of heating the interface direct heating the surfaces to be joined
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
- B29C65/16—Laser beams
- B29C65/1629—Laser beams characterised by the way of heating the interface
- B29C65/1654—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined
- B29C65/1661—Laser beams characterised by the way of heating the interface scanning at least one of the parts to be joined scanning repeatedly, e.g. quasi-simultaneous laser welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
- B29C65/16—Laser beams
- B29C65/1629—Laser beams characterised by the way of heating the interface
- B29C65/1664—Laser beams characterised by the way of heating the interface making use of several radiators
- B29C65/1667—Laser beams characterised by the way of heating the interface making use of several radiators at the same time, i.e. simultaneous laser welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
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- B29C66/1312—Single flange to flange joints, the parts to be joined being rigid
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- B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
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- B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
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Definitions
- the present invention generally relates to direct laser infrared (IR) welding for plastic components.
- the present invention is directed to a system and method for joining at least two plastic components together using direct laser IR welding.
- vibration laser welding is currently the prevalent approach used to join multiple plastic components together.
- alternative welding techniques such as conventional laser welding and infrared (IR) welding may be used as well to join multiple plastic components together.
- IR infrared
- These alternative welding techniques tend to produce higher quality weld joints and offer greater design freedom when compared to vibration welding. Nonetheless, these alternative welding techniques also have drawbacks as well, which limit the applications where they may be used.
- a first, optically transparent part and a second, absorbent part are provided, where the first part is positioned above the second part.
- the first part may be constructed of a transparent polymer that allows for IR energy from a laser beam to pass through.
- the second part may be treated with a material that acts to absorb the IR energy from the laser beam. For example, in one approach carbon black may be added to the second part to absorb IR energy from the laser beam.
- the first part and the second part are clamped together, and the IR energy from the laser beam passes through the first part.
- the IR energy from the laser beam melts an adjacent surface of the second part, which in turn welds the first part and the second part together.
- the first part and the second part are each constructed of dissimilar materials (i.e., the first part is constructed of a transparent material and the second part is constructed of a material that absorbs IR energy).
- a direct line of sight should be available through a relatively thin portion of the first part as well.
- the relatively thin portion of the first part is typically between about one to three millimeters. This requirement provides narrow design constraints, and limits the number of applications where laser welding may be used.
- heating elements such as, for example, quartz lamps or a heated filament may be provided to generate heat.
- the heat may be radiated directly upon the surfaces of the parts that are to be joined to one another. Specifically, the surfaces of the parts to be joined to one another may be melted. The melted surfaces of the parts may then be clamped against one another to create a weld.
- this problem may be further exacerbated if the parts have relatively complex geometry, as this makes uniform heating along the surfaces more difficult.
- the tooling associated with the heating elements may need to be customized depending on the application, which may add cost. Thus, there exists a need for a more cost-effective and flexible approach to weld plastic parts.
- a system for welding at least two plastic components together where the plastic components are welded together at respective joining surfaces.
- the system includes at least one infrared (IR) laser beam source positioned relative to the at least two plastic components and a control module.
- the IR laser beam source generates an IR laser beam.
- the control module is in operative communication with the at least one IR laser beam source.
- the control module includes control logic for controlling the at least one IR laser beam source to heat the joining surfaces of the at least two plastic components to a welding temperature.
- a method of welding at least two plastic components together comprises directing at least one infrared (IR) laser beam along the joining surfaces of the at least two plastic components.
- the IR laser beam heats the joining surfaces of the at least two plastic components to a welding temperature.
- the method also includes clamping the at least two plastic components together at the joining surfaces to create a weld.
- FIG. 1 is a schematic illustration of an exemplary system for heating at least two plastic components together using an IR laser source
- FIG. 2 is a schematic illustration of the two plastic components shown in FIG. 1 being clamped together after sufficient heating;
- FIG. 3 is a schematic illustration of an alternative embodiment of the system shown in FIG. 1 for heating at least two plastic components together;
- FIG. 4 is a schematic illustration of the two plastic components shown in FIG. 3 being clamped together after sufficient heating;
- FIG. 5 is a schematic illustration of another embodiment of the system shown in FIG. 1 for heating at least two plastic components together;
- FIG. 6 is a schematic illustration of the two plastic components shown in FIG. 5 being clamped together after sufficient heating.
- FIG. 1 illustrates an exemplary system 10 for welding at least two plastic components 20 a , 20 b together at their respective joining surfaces 22 a , 22 b .
- the system 10 may include a laser beam source 30 and a control module 32 in operative communication with the laser beam source 30 .
- the laser beam source 30 generates a laser beam 40 operating in the infrared (IR) portion of the electromagnetic spectrum, where a wavelength of the laser beam 40 generally ranges from about 750 nm to about 1 mm.
- the laser beam source 30 may include a solid-state laser, a diode laser, or a gas laser for generating the laser beam 40 .
- a solid-state laser is a fiber laser.
- the plastic components 20 a , 20 b may be underhood components in an automotive application.
- the control module 32 may refer to, or be part of, an application specific integrated circuit (ASIC), an electronic circuit, a combinational logic circuit, a field programmable gate array (FPGA), a processor (shared, dedicated, or group) that executes code, or a combination of some or all of the above, such as in a system-on-chip.
- the control module 32 may be used to control the laser beam source 30 in order to direct the laser beam 40 along the joining surfaces 22 a , 22 b of the plastic components 20 a , 20 b . In the embodiments as shown in FIGS.
- the laser beam source 30 is based on remote laser welding, which utilizes scanning mirrors (not illustrated) for positioning and moving the laser beam 40 along the joining surfaces 22 a , 22 b of the plastic components 20 a , 20 b .
- scanning mirrors not illustrated
- other techniques may be used to position the laser beam 40 along the joining surfaces 22 a , 22 b of the plastic components 20 a , 20 b as well.
- a robot or a Cartesian system may be used for positioning and moving the laser beam 40 along the joining surfaces 22 a , 22 b of the plastic components 20 a , 20 b.
- the plastic components 20 a , 20 b may be constructed of any type of thermoplastic polymer such as, but not limited to, polypropylene, polycarbonate, acrylic, nylon, and acrylonitrile butadiene styrene (ABS).
- the plastic components 20 a , 20 b may be constructed of the same material.
- the plastic components 20 a , 20 b may be constructed of different materials.
- an additive or colorant may be added to material the plastic components 20 a , 20 b are constructed of, where the colorant is configured to substantially absorb the energy emitted by the laser beam 40 .
- the colorant may be carbon black.
- the additive or colorant may be omitted from the plastic components 20 a , 20 b .
- a coating configured to substantially absorb energy in the IR spectrum may be applied the joining surfaces 22 a , 22 b of the plastic components 20 a , 20 b .
- CLEARWELD® One commercially available example of the coating is sold under the trade name CLEARWELD®, and is manufactured by the Gentex Corporation located in Binghamton, N.Y.
- the colorant may be omitted from the plastic components 20 a , 20 b .
- the coating is not applied to the joining surfaces 22 a , 22 b of the components 20 a , 20 b .
- the laser beam 40 includes a wavelength of at least about 2000 nm within the IR spectrum. If the laser beam 40 operates at a wavelength of at least 2000 nm, then the plastic components 20 a , 20 b may be able to substantially absorb the energy emitted by the laser beam 40 , even in the absence of the colorant or the coating applied to the joining surfaces 22 a , 22 b of the plastic components 20 a , 20 b.
- the plastic components 20 a , 20 b may be held in place using a fixture (not illustrated). In the non-limiting embodiment as shown in FIG. 1 , both of the plastic components 20 a , 20 b are positioned such that the joining surfaces 22 a , 22 b of the plastic components 20 a , 20 b generally oppose the laser beam source 30 .
- the control module 32 may be used to scan the laser beam 40 along both the joining surfaces 22 a , 22 b of the plastic components 20 a , 20 b .
- FIG. 1 both of the plastic components 20 a , 20 b are positioned such that the joining surfaces 22 a , 22 b of the plastic components 20 a , 20 b generally oppose the laser beam source 30 .
- the control module 32 may be used to scan the laser beam 40 along both the joining surfaces 22 a , 22 b of the plastic components 20 a , 20 b .
- control module 32 includes control logic or circuitry for controlling the laser beam source 30 to manipulate the laser beam 40 within a first welding area 50 a and a second welding area 50 b in order to melt the joining surfaces 22 a , 22 b of the plastic components 20 a , 20 b.
- the laser beam 40 rapidly scans repeatedly over both the joining surfaces 22 a , 22 b of the plastic components 20 a , 20 b in a quasi-simultaneous matter in order to sufficiently heat both of the joining surfaces 22 a , 22 b to a welding temperature at about the same time.
- the laser 40 scans and heats the surfaces 22 a , 22 b rapidly enough in order to keep the surfaces 22 a , 22 b at the welding temperature until the plastic components 20 a , 20 b are clamped together (the clamping is shown in FIG. 2 , and is described in greater detail below).
- the laser beam 40 may repeatedly scan over both the joining surfaces 22 a , 22 b at a rate of about 50,000 mm/second. This speed of the laser 40 translates into about ten to about two hundred passes per second along the joining surfaces 22 a , 22 b of the plastic components 20 a , 20 b , where the exact number of passes may depend on the specific size and geometry of the plastic components 20 a , 20 b .
- the welding temperature may vary based on the specific material that the plastic components 20 a , 20 b are constructed of. The welding temperature may be defined as a temperature at which the plastic components 20 a , 20 b melt sufficiently so that they may be fused together.
- the control module 32 may include control logic for adjusting various welding parameters of the laser beam 40 in order to accommodate the geometry of the joining surfaces 22 a , 22 b as well as the specific material that the plastic components 20 a , 20 b are constructed of Specifically, the welding parameters may control the amount of heat and melting the joining surfaces 22 a , 22 b may undergo as the laser beam 40 is scanned. Some examples of the welding parameters that the control module 32 may adjust include, but are not limited to, the travel speed of the laser beam 40 , the scanning frequency of the laser beam 40 , the duration at which the laser beam 40 heats the plastic components 20 a , 20 b , and a size of the laser focal diameter of the laser beam 40 .
- the laser beam 40 may wobble or quiver slightly as the laser beam 40 melts the joining surfaces 22 a , 22 b of the plastic components 20 a , 20 b , which also affects the amount of heat and melting the joining surfaces 22 a , 22 b may undergo.
- the welding parameters may also account for any unique features located along the joining surfaces 22 a , 22 b of the plastic components 20 a , 20 b .
- relatively small ribs may be positioned along the joining surfaces 22 a , 22 b of the plastic components 20 a , 20 b . The ribs may be used to accelerate the melting of the joining surfaces 22 a , 22 b.
- the welding parameters may be adjusted in order to achieve a specific amount of energy per unit of surface area of the joining surfaces 22 a , 22 b of the plastic components 20 a , 20 b .
- the specific amount of energy per unit of surface area generates enough heat for the joining surfaces 22 a , 22 b to melt sufficiently so that they may be fused together, but at the same time will not cause the plastic components 20 a , 20 b to overheat and burn.
- the specific amount of energy per unit of surface area may generate enough heat so that the joining surfaces 22 a , 22 b of the plastic components 20 a , 20 b remain melted as the plastic components 20 a , 20 b are clamped together to form a weld.
- the average energy per unit of surface area may range from about 0.055 W/mm 2 to about 0.5 W/mm 2 . It should be noted that if excessive energy is delivered to the joining surfaces 22 a , 22 b , the plastic components 20 a , 20 b may degrade or burn. For example, if a spot size of the laser beam 40 is relatively small, or if a scanning speed of the laser beam 40 is relatively slow, this may generate excessive energy along the joining surfaces 22 a , 22 b , which may cause burning. Moreover, if insufficient energy is delivered to the joining surfaces 22 a , 22 b , then the plastic components 20 a , 20 b may not be heated to the welding temperature.
- the plastic components 20 a , 20 b may be clamped together to form a weld.
- the fixture holding both the plastic components 20 a , 20 b may rotate both of the plastic components 20 a , 20 b by about ninety degrees, and towards one another such that the joining surfaces 20 a , 20 b face one another along a y-axis of orientation.
- the fixture (not illustrated) may then clamp the plastic components 20 a , 20 b together for a predetermined amount of time under a predetermined amount of pressure.
- the plastic components 20 a , 20 b may be clamped together with between about 1 MPa to about 4 MPa of clamping pressure for about five to twenty seconds. Clamping the plastic components 20 a , 20 b for the predetermined amount of time under the predetermined amount of pressure creates a weld (not shown) between the two joining surfaces 22 a , 22 b .
- the plastic components 20 a , 20 b may be welded or joined together in order to create a single, unitary part.
- a single laser beam source 30 is illustrated.
- the system 10 may utilize more than one laser beam source 30 as well.
- FIG. 3 a system 100 having multiple laser beam sources 130 a , 130 b is illustrated.
- the laser beam source 130 a may be used to melt a joining surface 122 a of a plastic component 120 a .
- the laser beam source 130 b may be used to melt a joining surface 122 b of a plastic component 120 b .
- Multiple laser beam sources 130 may be especially advantageous if surface areas of the joining surfaces 122 a , 122 b are relatively large, as a single laser beam may not always be able to scan the joining surfaces 122 a , 122 b frequently enough in order to melt the joining surfaces 122 a , 122 b sufficiently to create a weld.
- a control module 132 may be in operative communication with both the laser beam sources 130 a , 130 b .
- the control module 132 includes control logic or circuitry for controlling the laser beam sources 130 a , 130 b independently of one another.
- the control module 132 includes control logic or circuitry for controlling the laser beam source 130 a to manipulate a laser beam 140 a along a first welding area 150 a .
- the laser beam 40 travels within the first welding area 150 a in order to heat the joining surface 122 a of the plastic component 120 a to the welding temperature, thereby melting the joining surface 122 a .
- the control module 132 also controls the laser beam source 130 b to manipulate a laser beam 140 b along a second welding area 150 b .
- the laser beam 140 b travels within the second welding area 150 b in order to heat the joining surface 122 b of the plastic component 120 b to the welding temperature, thereby melting the joining surface 122 b .
- both joining surfaces 122 a , 122 b of the plastic components 120 a , 120 b may be melted together at the same time.
- the plastic components 120 a , 120 b may be welded together.
- the fixture holding both the plastic components 120 a , 120 b may rotate both of the plastic components 120 a , 120 b by about ninety degrees, and towards one another such that the joining surfaces 120 a , 120 b face one another in the y-axis orientation.
- the fixture (not illustrated) may then clamp the plastic components 120 a , 120 b together for the predetermined amount of time under the predetermined amount of pressure.
- FIG. 4 illustrates both the laser beam sources 130 a , 130 b being positioned directly adjacent or side-by-side with one another, it is to be understood that the laser beam sources 130 a , 130 b may be oriented in other configurations as well.
- FIG. 4 illustrates the plastic components 120 a , 120 b positioned side-by-side with one another, which each of the joining surfaces 122 a , 122 b facing upwardly towards the laser beam sources 130 a , 130 b , those skilled in the art will appreciate that the plastic components 120 a , 120 b may be positioned in different orientations as well.
- FIG. 5 a system 200 having multiple laser beam sources 230 a , 230 b is illustrated.
- a control module 232 may be in operative communication with both the laser beam sources 230 a , 230 b.
- FIG. 5 also illustrates two plastic components 220 a , 220 b that include respective joining surfaces 222 a , 222 b .
- One of the plastic components 220 a is oriented in a first position, where the joining surface 222 a is positioned in an upwards direction.
- the remaining plastic component 220 b has been rotated by about one hundred and eighty degrees and is oriented in a second position, where the joining surface 222 b is positioned in a downwards direction.
- the laser beam source 230 a is positioned above the joining surface 222 a of the plastic component 220 a .
- the laser beam source 230 a may be used to heat the joining surface 222 a of the plastic component 220 a to the welding temperature, thereby melting the joining surface 222 a .
- the control module 232 includes control logic or circuitry for controlling the laser beam source 230 a to manipulate a laser beam 240 a along a first welding area 250 a .
- the laser beam 240 a travels within the first welding area 250 a in order to heat the joining surface 222 a of the plastic component 220 a.
- the laser beam source 230 b is positioned below the joining surface 222 b of the plastic component 220 b .
- the laser beam source 230 b may be used to heat the joining surface 222 b of the plastic component 220 b to the welding temperature, thereby melting the joining surface 222 b .
- the control module 232 includes control logic or circuitry for controlling the laser beam source 230 b to manipulate a laser beam 240 b along a second welding area 250 b .
- the laser beam 240 b travels within the second welding area 250 b in order to melt the joining surface 222 b of the plastic component 220 b .
- the laser beam 240 a may melt the joining surface 222 a of the plastic component 220 a simultaneously as the laser beam 240 b melts the joining surface 222 b of the plastic component 220 b.
- the plastic components 220 a , 220 b may be welded together.
- the fixture holding both the plastic components 220 a , 220 b may translate one or both of the plastic components 220 a , 220 b in a linear direction towards one another such that the joining surfaces 120 a , 120 b face one another in an x-axis orientation.
- the fixture holding both the plastic components 220 a , 220 b may translate one or both of the plastic components 220 a , 220 b in a linear direction towards one another such that the joining surfaces 120 a , 120 b face one another in an x-axis orientation.
- the plastic component 220 b is translated in the linear direction towards the plastic component 220 a such that the joining surface 222 b of the plastic component 220 b generally opposes the joining surface 222 a of the plastic component 220 a .
- the fixture (not illustrated) may then clamp the plastic components 220 a , 220 b together for the predetermined amount of time under the predetermined amount of pressure.
- the disclosed systems each utilize direct IR welding to join at least two plastic components together.
- the disclosed laser beam generated by the IR laser beam source may directly scan and melt respective joining surfaces of the plastic components.
- conventional laser welding typically requires a first, optically transparent part and a second, absorbent part.
- the first part may be constructed of a transparent polymer that allows for IR energy from a laser beam to pass through.
- the second part may be treated with a material that acts to absorb the IR energy from the laser beam.
- the disclosed system does not require two parts constructed of dissimilar materials for welding.
- the disclosed system does not typically require custom tooling for welding, unlike IR welding.
- the disclosed system may also provide greater control as well as more consistent heating of the joining surfaces of the plastic parts when compared to IR welding.
Abstract
A system for welding at least two plastic components together is disclosed, where the plastic components are welded together at respective joining surfaces. The system includes at least one infrared (IR) laser beam source positioned relative to the at least two plastic components and a control module. The IR laser beam source generates an IR laser beam. The control module is in operative communication with the at least one IR laser beam source. The control module includes control logic for controlling the at least one IR laser beam source to heat the joining surfaces of the at least two plastic components to a welding temperature.
Description
- 1. Field of the Invention
- The present invention generally relates to direct laser infrared (IR) welding for plastic components. In particular, the present invention is directed to a system and method for joining at least two plastic components together using direct laser IR welding.
- 2. Description of the Related Art
- In the area of automotive underhood components such as intake manifolds, vibration laser welding is currently the prevalent approach used to join multiple plastic components together. However, alternative welding techniques such as conventional laser welding and infrared (IR) welding may be used as well to join multiple plastic components together. These alternative welding techniques tend to produce higher quality weld joints and offer greater design freedom when compared to vibration welding. Nonetheless, these alternative welding techniques also have drawbacks as well, which limit the applications where they may be used.
- In conventional laser welding, a first, optically transparent part and a second, absorbent part are provided, where the first part is positioned above the second part. The first part may be constructed of a transparent polymer that allows for IR energy from a laser beam to pass through. The second part may be treated with a material that acts to absorb the IR energy from the laser beam. For example, in one approach carbon black may be added to the second part to absorb IR energy from the laser beam. The first part and the second part are clamped together, and the IR energy from the laser beam passes through the first part. The IR energy from the laser beam melts an adjacent surface of the second part, which in turn welds the first part and the second part together. However, in conventional laser welding the first part and the second part are each constructed of dissimilar materials (i.e., the first part is constructed of a transparent material and the second part is constructed of a material that absorbs IR energy). Moreover, a direct line of sight should be available through a relatively thin portion of the first part as well. The relatively thin portion of the first part is typically between about one to three millimeters. This requirement provides narrow design constraints, and limits the number of applications where laser welding may be used.
- In IR welding, heating elements such as, for example, quartz lamps or a heated filament may be provided to generate heat. The heat may be radiated directly upon the surfaces of the parts that are to be joined to one another. Specifically, the surfaces of the parts to be joined to one another may be melted. The melted surfaces of the parts may then be clamped against one another to create a weld. However, it may be challenging to control the heating elements in order to achieve a constant or uniform temperature along the surfaces of the parts that are joined to one another. Moreover, this problem may be further exacerbated if the parts have relatively complex geometry, as this makes uniform heating along the surfaces more difficult. Finally, the tooling associated with the heating elements may need to be customized depending on the application, which may add cost. Thus, there exists a need for a more cost-effective and flexible approach to weld plastic parts.
- In one embodiment, a system for welding at least two plastic components together is disclosed, where the plastic components are welded together at respective joining surfaces. The system includes at least one infrared (IR) laser beam source positioned relative to the at least two plastic components and a control module. The IR laser beam source generates an IR laser beam. The control module is in operative communication with the at least one IR laser beam source. The control module includes control logic for controlling the at least one IR laser beam source to heat the joining surfaces of the at least two plastic components to a welding temperature.
- In another embodiment, a method of welding at least two plastic components together is disclosed. The two plastic components are welded together at respective joining surfaces. The method comprises directing at least one infrared (IR) laser beam along the joining surfaces of the at least two plastic components. The IR laser beam heats the joining surfaces of the at least two plastic components to a welding temperature. The method also includes clamping the at least two plastic components together at the joining surfaces to create a weld.
- For the purpose of illustrating the invention, the drawings show a form of the invention that is presently preferred. However, it should be understood that the present invention is not limited to the precise arrangements and instrumentalities shown in the drawings, wherein:
-
FIG. 1 is a schematic illustration of an exemplary system for heating at least two plastic components together using an IR laser source; -
FIG. 2 is a schematic illustration of the two plastic components shown inFIG. 1 being clamped together after sufficient heating; -
FIG. 3 is a schematic illustration of an alternative embodiment of the system shown inFIG. 1 for heating at least two plastic components together; -
FIG. 4 is a schematic illustration of the two plastic components shown inFIG. 3 being clamped together after sufficient heating; -
FIG. 5 is a schematic illustration of another embodiment of the system shown inFIG. 1 for heating at least two plastic components together; and -
FIG. 6 is a schematic illustration of the two plastic components shown inFIG. 5 being clamped together after sufficient heating. - Referring now to the drawings in which like reference numerals indicate like parts,
FIG. 1 illustrates anexemplary system 10 for welding at least twoplastic components surfaces system 10 may include alaser beam source 30 and acontrol module 32 in operative communication with thelaser beam source 30. Thelaser beam source 30 generates alaser beam 40 operating in the infrared (IR) portion of the electromagnetic spectrum, where a wavelength of thelaser beam 40 generally ranges from about 750 nm to about 1 mm. For example, thelaser beam source 30 may include a solid-state laser, a diode laser, or a gas laser for generating thelaser beam 40. One specific example of a solid-state laser is a fiber laser. In one non-limiting embodiment, theplastic components - The
control module 32 may refer to, or be part of, an application specific integrated circuit (ASIC), an electronic circuit, a combinational logic circuit, a field programmable gate array (FPGA), a processor (shared, dedicated, or group) that executes code, or a combination of some or all of the above, such as in a system-on-chip. Thecontrol module 32 may be used to control thelaser beam source 30 in order to direct thelaser beam 40 along thejoining surfaces plastic components FIGS. 1-6 , thelaser beam source 30 is based on remote laser welding, which utilizes scanning mirrors (not illustrated) for positioning and moving thelaser beam 40 along thejoining surfaces plastic components laser beam 40 along thejoining surfaces plastic components laser beam 40 along thejoining surfaces plastic components - The
plastic components plastic components plastic components plastic components laser beam 40. For example, in one embodiment, the colorant may be carbon black. In another embodiment, the additive or colorant may be omitted from theplastic components surfaces plastic components - In yet another embodiment, the colorant may be omitted from the
plastic components surfaces components laser beam 40 includes a wavelength of at least about 2000 nm within the IR spectrum. If thelaser beam 40 operates at a wavelength of at least 2000 nm, then theplastic components laser beam 40, even in the absence of the colorant or the coating applied to the joiningsurfaces plastic components - The
plastic components FIG. 1 , both of theplastic components surfaces plastic components laser beam source 30. Thecontrol module 32 may be used to scan thelaser beam 40 along both the joiningsurfaces plastic components FIG. 1 , thecontrol module 32 includes control logic or circuitry for controlling thelaser beam source 30 to manipulate thelaser beam 40 within afirst welding area 50 a and asecond welding area 50 b in order to melt the joiningsurfaces plastic components - The
laser beam 40 rapidly scans repeatedly over both the joiningsurfaces plastic components surfaces laser 40 scans and heats thesurfaces surfaces plastic components FIG. 2 , and is described in greater detail below). For example, in one non-limiting embodiment, thelaser beam 40 may repeatedly scan over both the joiningsurfaces laser 40 translates into about ten to about two hundred passes per second along the joiningsurfaces plastic components plastic components plastic components plastic components - The
control module 32 may include control logic for adjusting various welding parameters of thelaser beam 40 in order to accommodate the geometry of the joiningsurfaces plastic components surfaces laser beam 40 is scanned. Some examples of the welding parameters that thecontrol module 32 may adjust include, but are not limited to, the travel speed of thelaser beam 40, the scanning frequency of thelaser beam 40, the duration at which thelaser beam 40 heats theplastic components laser beam 40. Additionally, in one embodiment, thelaser beam 40 may wobble or quiver slightly as thelaser beam 40 melts the joiningsurfaces plastic components surfaces - Moreover, in one embodiment the welding parameters may also account for any unique features located along the joining
surfaces plastic components surfaces plastic components surfaces - The welding parameters may be adjusted in order to achieve a specific amount of energy per unit of surface area of the joining
surfaces plastic components surfaces plastic components surfaces plastic components plastic components plastic components surfaces plastic components laser beam 40 is relatively small, or if a scanning speed of thelaser beam 40 is relatively slow, this may generate excessive energy along the joiningsurfaces surfaces plastic components - Once the joining
surfaces plastic components plastic components FIG. 2 , the fixture holding both theplastic components plastic components surfaces plastic components plastic components plastic components surfaces plastic components - In the embodiment as shown in
FIG. 1 , a singlelaser beam source 30 is illustrated. However, those skilled in the art will appreciate that thesystem 10 may utilize more than onelaser beam source 30 as well. Turning toFIG. 3 , asystem 100 having multiplelaser beam sources laser beam source 130 a may be used to melt a joiningsurface 122 a of aplastic component 120 a. Similarly, thelaser beam source 130 b may be used to melt a joiningsurface 122 b of aplastic component 120 b. Multiple laser beam sources 130 may be especially advantageous if surface areas of the joiningsurfaces surfaces surfaces - A
control module 132 may be in operative communication with both thelaser beam sources control module 132 includes control logic or circuitry for controlling thelaser beam sources control module 132 includes control logic or circuitry for controlling thelaser beam source 130 a to manipulate alaser beam 140 a along afirst welding area 150 a. Thelaser beam 40 travels within thefirst welding area 150 a in order to heat the joiningsurface 122 a of theplastic component 120 a to the welding temperature, thereby melting the joiningsurface 122 a. Simultaneously, thecontrol module 132 also controls thelaser beam source 130 b to manipulate alaser beam 140 b along asecond welding area 150 b. Thelaser beam 140 b travels within thesecond welding area 150 b in order to heat the joiningsurface 122 b of theplastic component 120 b to the welding temperature, thereby melting the joiningsurface 122 b. Thus, both joiningsurfaces plastic components - Once the joining
surfaces plastic components plastic components FIG. 4 , the fixture holding both theplastic components plastic components surfaces plastic components - Although
FIG. 4 illustrates both thelaser beam sources laser beam sources FIG. 4 illustrates theplastic components surfaces laser beam sources plastic components FIG. 5 , asystem 200 having multiplelaser beam sources control module 232 may be in operative communication with both thelaser beam sources -
FIG. 5 also illustrates twoplastic components surfaces plastic components 220 a is oriented in a first position, where the joiningsurface 222 a is positioned in an upwards direction. The remainingplastic component 220 b has been rotated by about one hundred and eighty degrees and is oriented in a second position, where the joiningsurface 222 b is positioned in a downwards direction. - The
laser beam source 230 a is positioned above the joiningsurface 222 a of theplastic component 220 a. Thelaser beam source 230 a may be used to heat the joiningsurface 222 a of theplastic component 220 a to the welding temperature, thereby melting the joiningsurface 222 a. Specifically, thecontrol module 232 includes control logic or circuitry for controlling thelaser beam source 230 a to manipulate alaser beam 240 a along afirst welding area 250 a. Thelaser beam 240 a travels within thefirst welding area 250 a in order to heat the joiningsurface 222 a of theplastic component 220 a. - The
laser beam source 230 b is positioned below the joiningsurface 222 b of theplastic component 220 b. Thelaser beam source 230 b may be used to heat the joiningsurface 222 b of theplastic component 220 b to the welding temperature, thereby melting the joiningsurface 222 b. Specifically, thecontrol module 232 includes control logic or circuitry for controlling thelaser beam source 230 b to manipulate alaser beam 240 b along asecond welding area 250 b. Thelaser beam 240 b travels within thesecond welding area 250 b in order to melt the joiningsurface 222 b of theplastic component 220 b. It should be noted that thelaser beam 240 a may melt the joiningsurface 222 a of theplastic component 220 a simultaneously as thelaser beam 240 b melts the joiningsurface 222 b of theplastic component 220 b. - Once the joining
surfaces plastic components plastic components FIG. 6 , the fixture holding both theplastic components plastic components surfaces FIG. 6 , theplastic component 220 b is translated in the linear direction towards theplastic component 220 a such that the joiningsurface 222 b of theplastic component 220 b generally opposes the joiningsurface 222 a of theplastic component 220 a. The fixture (not illustrated) may then clamp theplastic components - Referring generally to
FIGS. 1-6 , the disclosed systems each utilize direct IR welding to join at least two plastic components together. Specifically, the disclosed laser beam generated by the IR laser beam source may directly scan and melt respective joining surfaces of the plastic components. In contrast, conventional laser welding typically requires a first, optically transparent part and a second, absorbent part. The first part may be constructed of a transparent polymer that allows for IR energy from a laser beam to pass through. The second part may be treated with a material that acts to absorb the IR energy from the laser beam. In contrast, the disclosed system does not require two parts constructed of dissimilar materials for welding. Moreover, the disclosed system does not typically require custom tooling for welding, unlike IR welding. The disclosed system may also provide greater control as well as more consistent heating of the joining surfaces of the plastic parts when compared to IR welding. - Although the invention has been described and illustrated with respect to exemplary embodiments thereof, it should be understood by those skilled in the art that the foregoing and various other changes, omissions and additions may be made therein and thereto, without parting from the spirit and scope of the present invention. Accordingly, other embodiments are within the scope of the following claims.
Claims (20)
1. A system for welding at least two plastic components together, wherein the at least two plastic components are welded together at respective joining surfaces, the system comprising:
at least one infrared (IR) laser beam source positioned relative to the at least two plastic components, wherein the at least one IR laser beam source generates an IR laser beam; and
a control module in operative communication with the at least one IR laser beam source, the control module including control logic for controlling the at least one IR laser beam source to heat the joining surfaces of the at least two plastic components to a welding temperature.
2. The system as recited in claim 1 , wherein the control module includes control logic for adjusting at least one welding parameter of the IR laser beam.
3. The system as recited in claim 2 , wherein the at least one welding parameter includes at least one of a travel speed of the IR laser beam, a scanning frequency of the IR laser beam, a duration at which the IR laser beam heats the at least two plastic components, and a size of a laser focal diameter of the IR laser beam.
4. The system as recited in claim 1 , wherein the control module includes control logic for controlling a specific amount of energy per surface area created along the joining surfaces of the at least two plastic components.
5. The system of claim 1 , further comprising a second IR laser beam source.
6. The system of claim 5 , wherein the second IR laser beam source is positioned directly adjacent to the at least one IR laser beam source, and wherein the second IR laser beam generates a second IR laser beam for heating at least one of the joining surfaces of the at least two plastic components to the welding temperature.
7. The system of claim 5 , wherein the at least one IR laser beam source is positioned above a first joining surface of a first plastic component, and the second IR laser beam source is positioned below a second joining surface of a second plastic component.
8. The system of claim 1 , wherein the IR laser beam includes a wavelength of least about 2000 nm.
9. The system of claim 1 , wherein the at least one IR laser beam source is one of a diode laser, a solid-state laser, and a gas laser.
10. A method of welding at least two plastic components together, wherein the at least two plastic components are welded together at respective joining surfaces, the method comprising:
directing at least one infrared (IR) laser beam along the joining surfaces of the at least two plastic components, wherein the at least one IR laser beam heats the joining surfaces of the at least two plastic components to a welding temperature; and
clamping the at least two plastic components together at the joining surfaces to create a weld.
11. The method as recited in claim 10 , comprising adjusting at least one welding parameter of the at least one IR laser beam.
12. The method as recited in claim 11 , wherein the at least one welding parameter includes at least one of a travel speed of the at least one IR laser beam, a scanning frequency of the at least one IR laser beam, a duration at which the at least one IR laser beam heats the at least two plastic components, and a size of a laser focal diameter of the at least one IR laser beam.
13. The method as recited in claim 10 , comprising controlling a specific amount of energy per surface area created along the joining surfaces of the at least two plastic components.
14. The method as recited in claim 10 , comprising a second IR laser beam, wherein the at least one IR laser beam melts a first joining surface of a first plastic component and the second IR laser melts a second joining surface of a second plastic component.
15. The method as recited in claim 10 , comprising rotating both the at least two plastic components by about ninety degrees before clamping.
16. The method as recited in claim 10 , comprising translating at least one of the at least two plastic components in a linear direction before clamping such that a first joining surface of a first plastic component generally opposes a second joining surface of a second plastic component.
17. The method as recited in claim 10 , comprising applying a coating to the joining surfaces of the at least two plastic components.
18. The method as recited in claim 10 , comprising adding a colorant to a material the at least two plastic components are constructed of, and wherein the colorant absorbs energy emitted by the IR laser beam.
19. The method as recited in claim 10 , wherein the at least one IR laser beam includes a wavelength of least about 2000 nm.
20. The method as recited in claim 10 , wherein the wherein the at least one IR laser beam is generated by at least one IR laser beam source, and wherein the at least one IR laser beam source is one of a diode laser, a solid-state laser, and a gas laser.
Priority Applications (3)
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US14/228,347 US20150273808A1 (en) | 2014-03-28 | 2014-03-28 | System and method for direct infrared (ir) laser welding |
EP15161007.8A EP2923821B1 (en) | 2014-03-28 | 2015-03-26 | Method for direct infrared laser welding |
US15/438,004 US11110665B2 (en) | 2014-03-28 | 2017-02-21 | System and method for direct infrared (IR) laser welding |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US14/228,347 US20150273808A1 (en) | 2014-03-28 | 2014-03-28 | System and method for direct infrared (ir) laser welding |
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US15/438,004 Division US11110665B2 (en) | 2014-03-28 | 2017-02-21 | System and method for direct infrared (IR) laser welding |
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US20150273808A1 true US20150273808A1 (en) | 2015-10-01 |
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US15/438,004 Active US11110665B2 (en) | 2014-03-28 | 2017-02-21 | System and method for direct infrared (IR) laser welding |
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US15/438,004 Active US11110665B2 (en) | 2014-03-28 | 2017-02-21 | System and method for direct infrared (IR) laser welding |
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US10591719B2 (en) * | 2017-12-19 | 2020-03-17 | Microvision, Inc. | Laser welded scanner assemblies |
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Also Published As
Publication number | Publication date |
---|---|
EP2923821A1 (en) | 2015-09-30 |
EP2923821B1 (en) | 2019-08-07 |
US20170157838A1 (en) | 2017-06-08 |
US11110665B2 (en) | 2021-09-07 |
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