Method for laser seam welding of moving workpieces

Claim 1

A method for continuous seam welding of at least two thin flexible strips of sheet material composed of a highly conductive metal selected from the group consisting of aluminum, copper and brass, having a thickness in the range of from about 0.001 to about 1/4 inch, while the strips are moving at a relatively high rate of speed of at least about 100 feet per minute, comprising the steps of: (a) directing the moving strips toward one another to form a converging Vee between the moving strips; (b) providing a pair of pressure rollers; (c) passing the moving strips between the pair of pressure rollers; (d) applying a force of above zero pounds against the moving strips with the pair of pressure rollers at a location contiguous to the point at which the moving strips converge such that the moving strips overlay one another in intimate contact at the point of convergence; (e) generating a laser beam of energy; (f) providing an optical medium for focusing said laser beam; (g) focusing said laser beam with said optical medium to produce a converging beam of laser energy having a predetermined focal length; and (h) directing said converging beam of laser energy into said converging Vee with its focal point located substantially about said point of convergence, the focal length of said converging beam being chosen in relation to the diameter of said pressure rollers such that when said converging beam is directed into said converging Vee said beam impinges upon the moving strips in the vicinity of the converging Vee closest to said point of convergence so as to minimize energy losses due to reflection and absorbed heat and to optimize the amount of energy that is available at said point of convergence for welding said strips together while moving at said high rate of speed.

Claim 2

A method for continuous seam welding of at least two thin flexible strips of sheet material composed of a highly conductive metal selected from the group consisting of aluminum, copper and brass, having a thickness in the range of from about 0.001 to about 1/4 inch, while the strips are moving at a relatively high rate of speed of at least about 100 feet per minute, comprising the steps of: (a) directing the moving strips toward one another to form a converging Vee between the moving strips; (b) providing a pair of pressure rollers; (c) passing the moving strips between the pair of pressure rollers; (d) applying a force of above zero pounds against the moving strips with the pair of pressure rollers at a location contiguous to the point at which the moving strips converge such that the moving strips overlay one another in intimate contact at the point of convergence; (e) generating a laser beam of energy; (f) providing an optical medium for focusing said laser beam; (g) focusing said laser beam with said optical medium to produce a converging beam of laser energy having a predetermined focal length; and (h) directing said converging beam of laser energy into said converging Vee with its focal point located substantially about said point of convergence, the focal length of said converging beam being chosen in relation to the diameter of said pressure rollers such that when said converging beam is directed into said converging Vee said beam impinges upon the moving strips in the vicinity of the converging Vee closest to said point of convergence so as to minimize energy losses due to reflection and absorbed heat and to optimize the amount of energy that is available at said point of convergence for welding said strips together while moving at said high rate of speed.

Claim 8

A method for continuous seam welding of at least two thin flexible strips of sheet material composed of a highly conductive metal selected from the group consisting of aluminum, copper and brass, having a thickness in the range of from about 0.001 to about 1/4 inch, while the strips are moving at a relatively high rate of speed of at least about 100 feet per minute, comprising the steps of: (a) directing the moving strips toward one another to form a converging Vee between the moving strips; (b) providing guide means for the moving strips having a curvilinear contour; (c) passing the moving strips over said guide means so that the moving strips converge toward one another in a curvilinear fashion; (d) applying a force of above zero pounds against the moving strips with said guide means at a location contiguous to the point at which the moving strips converge such that the moving strips overlay one another in intimate contact at the point of convergence; (e) generating a laser beam of energy; (f) providing an optical medium for focusing said laser beam; (g) focusing said laser beam with said optical medium to produce a converging beam of laser energy having a predetermined focal length; and (h) directing said converging beam of laser energy into said converging Vee with its focal point located substantially about said point of convergence, the focal length of said converging beam being chosen in relation to the radius of curvature of said guide means such that when said converging beam is directed into said converging Vee said beam impinges upon the moving strips in the vicinity of the converging Vee closest to the point of convergence so as to minimize energy losses due to reflection and absorbed heat and to optimize the amount of energy that is available at said point of convergence for welding said strips together while moving at said high rate of speed.

Claim 9

A method for continuous seam welding of at least two thin flexible strips of sheet material composed of a highly conductive metal selected from the group consisting of aluminum, copper and brass, having a thickness in the range of from about 0.001 to about 1/4 inch, while the strips are moving at a relatively high rate of speed of at least about 100 feet per minute, comprising the steps of: (a) directing the moving strips toward one another to form a converging Vee between the moving strips; (b) providing guide means for the moving strips having a curvilinear contour; (c) passing the moving strips over said guide means so that the moving strips converge toward one another in a curvilinear fashion; (d) applying a force of above zero pounds against the moving strips with said guide means at a location contiguous to the point at which the moving strips converge such that the moving strips overlay one another in intimate contact at the point of convergence; (e) generating a laser beam of energy; (f) providing an optical medium for focusing said laser beam; (g) focusing said laser beam with said optical medium to produce a converging beam of laser energy having a predetermined focal length; and (h) directing said converging beam of laser energy into said converging Vee with its focal point located substantially about said point of convergence, the focal length of said converging beam being chosen in relation to the radius of curvature of said guide means such that when said converging beam is directed into said converging Vee said beam impinges upon the moving strips in the vicinity of the converging Vee closest to the point of convergence so as to minimize energy losses due to reflection and absorbed heat and to optimize the amount of energy that is available at said point of convergence for welding said strips together while moving at said high rate of speed.

Claim 10

A method for continuous seam welding of at least two thin flexible strips of metallic sheet material having a thickness in the range of from about 0.001 to about 1/4 inch and having reflective surfaces, while the strips are moving at a relatively high rate of speed of at least about 100 feet per minute, comprising the steps of: (a) directing the moving strips toward one another to form a converging Vee between the moving strips with the reflective surfaces facing one another; (b) providing a pair of pressure rollers; (c) passing the moving strips between the pair of pressure rollers; (d) applying a force of above zero pounds against the moving strips with the pair of pressure rollers at a location contiguous to the point at which the moving strips converge such that the moving strips overlay one another in intimate contact at the point of convergence; (e) generating a laser beam of energy; (f) providing an optical medium for focusing said laser beam; (g) focusing said laser beam with said optical medium to produce a converging beam of laser energy having a predetermined focal length; and (h) directing said converging beam of laser energy into said converging Vee with its focal point located substantially about said point of convergence, the focal length of said converging beam being chosen in relation to the diameter of said pressure rollers such that when said converging beam is directed into said converging Vee said beam strikes the moving strips in the vicinity of the converging Vee closest to said point of convergence and is reflected by the moving strips in a direction toward said point of convergence so as to minimize energy losses due to reflection and absorbed heat and to optimize the amount of energy that is available at said point of convergence for welding said strips together while moving at said high rate of speed.

Claim 11

A method for continuous seam welding of at least two thin flexible strips of metallic sheet material having a thickness in the range of from about 0.001 to about 1/4 inch and having reflective surfaces, while the strips are moving at a relatively high rate of speed of at least about 100 feet per minute, comprising the steps of: (a) directing the moving strips toward one another to form a converging Vee between the moving strips with the reflective surfaces facing one another; (b) providing a pair of pressure rollers; (c) passing the moving strips between the pair of pressure rollers; (d) applying a force of above zero pounds against the moving strips with the pair of pressure rollers at a location contiguous to the point at which the moving strips converge such that the moving strips overlay one another in intimate contact at the point of convergence; (e) generating a laser beam of energy; (f) providing an optical medium for focusing said laser beam; (g) focusing said laser beam with said optical medium to produce a converging beam of laser energy having a predetermined focal length; and (h) directing said converging beam of laser energy into said converging Vee with its focal point located substantially about said point of convergence, the focal length of said converging beam being chosen in relation to the diameter of said pressure rollers such that when said converging beam is directed into said converging Vee said beam strikes the moving strips in the vicinity of the converging Vee closest to said point of convergence and is reflected by the moving strips in a direction toward said point of convergence so as to minimize energy losses due to reflection and absorbed heat and to optimize the amount of energy that is available at said point of convergence for welding said strips together while moving at said high rate of speed.