# US 7,407,338 B2 · Taper-lock laser weld for an air induction component

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- Number: US 7,407,338 B2
- Document ID: US7407338B2
- Status: Granted
- Kind: B2
- Application number: 10/674,623
- Filed: 2003-09-30
- Published: 2004-04-08
- Granted: 2008-08-05
- Earliest claimed: 2002-10-02
- Assignees: Mahle International GmbH
- Inventors: Bobbye Kaye Whitenton Baylis; Daniel Frank Watt; Xiao Qun Xu; James Vanderveen
- Web page: https://patentgrep.com/patent/US7407338B2

## CPC

- F02M 35/10144: {Connections of intake ducts to each other or to another device}
- B23K 33/00: Specially-profiled edge portions of workpieces for making soldering or welding connections; Filling the seams formed thereby
- B29C 65/1635: {at least passing through one of the parts to be joined, i.e. laser transmission welding}
- B29C 65/7841: {Holding or clamping means for handling purposes (clamping means for the purpose of applying pressure on the parts to be joined, in the area to be joined B29C66/81; work holders in general B25B; devices for holding or positioning work for welding metal B23K37/04)}
- B29C 66/124: {Tongue and groove joints}
- B29C 66/12449: {being asymmetric (B29C66/12445 takes precedence)}
- B29C 66/12469: {being asymmetric}
- B29C 66/12841: {comprising at least two butt joint-segments}
- B29C 66/1286: {comprising at least one bevelled joint-segment}
- B29C 66/54: {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}
- B29C 66/8262: {using "pressure means" which are associated with at least one of the parts to be joined and remain in or on it}
- B29C 66/8322: {Joining or pressing tools reciprocating along one axis}
- B29C 66/83221: {cooperating reciprocating tools, each tool reciprocating along one axis}
- F02M 35/10321: {Plastics; Composites; Rubbers}
- F02M 35/1036: {by welding, bonding or the like (welding plastic materials together in general B29C65/02)}
- B29C 66/5344: {said single elements being substantially annular, i.e. of finite length, e.g. joining flanges to tube ends (B29C66/5346 takes precedence)}
- B29C 66/73921: {characterised by the materials of both parts being thermoplastics}
- B29K 2995/0027: for light outside the visible spectrum
- B29L 2031/7492: {Intake manifold}
- Y10T 403/477: Fusion bond, e.g., weld, etc.
- Y10T 403/76: having a cam, wedge, or tapered portion
- F02M: SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- 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 (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A transparent component portion includes a first weld surface and a first taper locking surface formed opposite from the first weld surface. An absorbing component portion includes a second weld surface and a second taper locking surface formed opposite from the second weld surface. The first and second taper locking surfaces cooperate to force and lock the first and second weld surfaces into abutting engagement for laser welding.

## Claims

### Claim 1

An air induction component assembly comprising:
a first shell made from a laser-transparent material defining a first laser weld surface and including a first taper locking surface opposite from said first laser weld surface;
a second shell made from a laser absorbing material defining a second laser weld surface and including a second taper locking surface opposite from said second laser weld surface wherein said first laser weld surface comprises a first tapered surface portion defining a first angle and said second laser weld surface comprises a second tapered surface portion defining a second angle different than said first angle; and
a laser weld joint area formed at said first and second laser weld surfaces to permanently attach said first shell to said second shell wherein said first and second taper locking surfaces cooperate with each other to lock said first and second laser weld surfaces into abutting engagement at a predetermined pressure during a laser welding process, and wherein at least one of said first and second taper locking surfaces defines a taper angle that is at least twice that of both said first and second angles.

### Claim 2 (depends on 1)

An air induction component assembly as set forth in claim 1 wherein the predetermined pressure is at least 190 pounds per square inch (psi).

### Claim 3 (depends on 1)

An air induction component assembly as set forth in claim 1 wherein a laser beam is applied generally perpendicular to at least one of said first and second tapered surfaces.

### Claim 4

An air induction component assembly comprising:
a first shell made from a laser-transparent material defining a first laser weld surface and including a first taper locking surface opposite from said first laser weld surface wherein said first shell includes a first wall extension having an inner wall surface and an outer wall surface, said first wall extension extending from a first base end to a first distal end with said first laser weld surface and said first taper locking surface being formed on said first wall extension;
a second shell made from a laser absorbing material defining a second laser weld surface and including a second taper locking surface opposite from said second laser weld surface wherein said first laser weld surface comprises a first tapered surface portion defining a first angle and said second laser weld surface comprises a second tapered surface portion defining a second angle different than said first angle, and wherein said second shell includes a second wall extension having an inner wall surface and an outer wall surface, said second wall extension extending from a second base end to a second distal end with said second laser weld surface and said second taper locking surface being formed on said second wall extension, and wherein said first and said second wall extensions overlap each other such that said first and said second taper locking surfaces directly abut each other; and
a laser weld joint area formed at said first and second laser weld surfaces to permanently attach said first shell to said second shell wherein said first and second taper locking surfaces cooperate with each other to lock said first and second laser weld surfaces into abutting engagement at a predetermined pressure during a laser welding process.

### Claim 5 (depends on 4)

An air induction component assembly as set forth in claim 4 wherein said first laser weld surface tapers to a flat surface formed at said first distal end, said flat surface transitioning from said first laser weld surface to said first taper locking surface.

### Claim 6 (depends on 5)

An air induction component assembly as set forth in claim 5 including a first ledge surface transitioning from said inner wall surface of said first wall extension to said first laser weld surface, and a second ledge surface transitioning from said outer wall surface of said first wall extension to said fist taper locking surface.

### Claim 7 (depends on 6)

An air induction component assembly as set forth in claim 6 wherein said second laser weld surface tapers to a curved surface formed near said second base end, said curved surface transitioning from said second laser weld surface to said second taper locking surface.

### Claim 8 (depends on 7)

An air induction component assembly as set forth in claim 7 including a third ledge surface transitioning from said inner wall of said second wall extension to said second laser weld surface, and a fourth ledge surface transitioning from said outer wall surface of said second wall extension to said second taper locking surface.

### Claim 9 (depends on 8)

An air induction component assembly as set forth in claim 8 wherein said first and third ledge surfaces are spaced apart from each other to form a first gap when said first and second laser weld surfaces are locked into abutting engagement by said first and second laser locking surfaces.

### Claim 10 (depends on 9)

An air induction component assembly as set forth in claim 9 wherein said second and fourth ledge surfaces are in direct contact with each other when said first and second laser weld surfaces are locked into abutting engagement by said first and second laser locking surfaces.

### Claim 11 (depends on 9)

An air induction component assembly as set forth in claim 9 wherein said flat surface is spaced apart from said curved surface to form a second gap when said first and second laser weld surfaces are locked into abutting engagement by said first and second laser locking surfaces.

### Claim 12

An air induction component assembly comprising:
a first shell made from a laser-transparent material defining a first laser weld surface and including a first taper locking surface opposite from said first laser weld surface, and wherein said first shell includes a first transition surface that transitions from said first laser weld surface to said first taper locking surface;
a second shell made from a laser absorbing material defining a second laser weld surface and including a second taper locking surface opposite from said second laser weld surface, and wherein said second shell includes a second transition surface that transitions from said second laser weld surface to said second taper locking surface, and wherein said first laser weld surface comprises a first laser surface portion defining a first angle and said second laser weld surface comprises a second tapered surface portion defining a second angle different than said first angle;
said first transition surface including a flat segment and said second transition surface including a curved segment that directly faces said flat; and
a laser weld joint area formed at said first and second laser weld surfaces to permanently attach said first shell to said second shell wherein said first and second taper locking surfaces cooperate with each other to lock said first and second laser weld surfaces into abutting engagement at a predetermined pressure during a laser welding process.