An adjustable rectangular spot laser soldering lens
Patent Information
- Application Number
- CN202522204666.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-10-19
- Publication Date
- 2026-09-11
- Estimated Expiration
- 2035-10-19
AI Technical Summary
[0004]基于上述表述，本实用新型提供了 一种可调矩形光斑的激光焊锡镜头，以解决现有矩形激光焊锡镜头在光斑宽高比可控性、双光源协同性、调节精度及光路集成性等方面存在显著缺陷，无法适应电子制造行业对精密焊接的高效化、多样化需求的缺点
1、本申请根据现有矩形激光焊锡镜头进行改进，采用“双光源 + 独立调节单元”的核心设计，主光源通过 X 轴柱面透镜与 Y 轴柱面透镜的协同作用，可实现宽高比 1:5-5:1 的大范围调节，覆盖从细长引脚到正方形焊盘（近 1:1 光斑）的全场景需求；副光源可根据焊接工件的规格，选择性配置 X 轴或 Y 轴柱面透镜，实现与主光源的光斑参数互补或同步调节，避免现有技术 “单光源固定透镜” 需频繁换件的问题，同时消除拆装误差，显著提升生产效率与焊接精度；
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Figure CN224737476U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of laser lens technology, specifically to a laser soldering lens with an adjustable rectangular spot. Background Technology
[0002] As the electronics manufacturing industry upgrades towards miniaturization and precision, laser soldering technology, with its advantages of a small heat-affected zone and precise solder joint positioning, has become a core technology for soldering precision components such as PCB boards, chip leads, and micro connectors. In actual production, different specifications of solder joints have clearly differentiated requirements for the shape and aspect ratio of the laser spot: for example, when soldering slender chip leads, a narrow rectangular spot is required to avoid thermal short circuits between adjacent leads; when soldering nearly square chip pads, a rectangular spot with a near 1:1 ratio is needed to ensure uniform energy distribution at the solder joint. Therefore, the controllability, adjustment precision, and dual-light source synergy of the laser soldering lens's spot aspect ratio directly determine the soldering efficiency and product yield. However, current laser soldering lens technology still has many bottlenecks, making it difficult to meet the diverse needs of precision soldering. Specific shortcomings are as follows: 1. Limited Aspect Ratio Adjustment Capability and Reliance on Frequent Component Replacement: Existing laser soldering lenses mostly adopt a "single light source + fixed lens group" design, which can only output a single-shaped spot (such as a circle or a rectangle with a fixed aspect ratio). When it is necessary to adapt to solder joints with different aspect ratios, the lens must be disassembled and a special lens assembly must be replaced. This process is not only time-consuming, but also prone to spot positioning deviations due to disassembly and assembly errors (the deviation can reach 5-10μm), which reduces production efficiency and increases the risk of cold solder joints and over-soldering. Some lenses that claim to have adjustable spot ratios can only finely adjust the lens position in a single direction by manually turning a mechanical knob. The adjustment range is narrow (the aspect ratio adjustment range is usually only 1:2-2:1), and the accuracy is low, which cannot meet the requirements of micron-level precision solder joints. 2. Poor stability and low automation of the adjustment unit: Existing lenses mostly use a "bolt-fixed + manual push" installation method for the adjustment lens, lacking a reliable guiding and driving structure. On the one hand, manual adjustment makes it difficult to accurately control the displacement of the lens, especially when adjusting in both directions of the X and Y axes, which easily leads to overshoot or deviation, resulting in loss of control over the aspect ratio of the light spot. On the other hand, the adjusted lens lacks a locking and vibration-damping structure, and equipment vibration during the welding process can easily cause the lens to shift (the displacement can reach 3-5μm), causing the light spot shape to drift, which in turn leads to fluctuations in the weld quality. Even if some lenses use motor drive, they are mostly stepper motors with simple slide rails, and the adjustment accuracy (±0.1mm) cannot match the micron-level displacement requirements of cylindrical lenses, making it difficult to achieve precise control of the aspect ratio of the light spot. 3. Poor optical path integration and insufficient adaptability: Existing technologies do not have an integrated design for the transmission and focusing of rectangular light spots. For example, some beam-splitting units do not use polarization beam splitters, resulting in inconsistent polarization states of the main and secondary light sources, and stray light appearing at the edge of the focused light spot. Some lenses do not have refracting mirrors set for the path of the main light source, resulting in inconsistent optical path directions of the main and secondary light sources (e.g., the main light source is horizontal and the secondary light source is vertical), which requires additional equipment space and is not conducive to integration into miniaturized welding equipment. At the same time, the spacing between the adjusting lens, focusing lens, and galvanometer lacks optimized design, resulting in increased energy loss of the beam during transmission and reduced energy density of the focused light spot, affecting welding efficiency.
[0003] In summary, existing laser soldering lenses have significant shortcomings in terms of spot aspect ratio controllability, dual-light source synergy, adjustment precision, and optical path integration, making it difficult to meet the high-efficiency and diversified demands of the electronics manufacturing industry for precision soldering. Therefore, developing a rectangular laser soldering lens with precisely controllable spot aspect ratio, optimized dual-light source synergy, and stable and reliable adjustment is key to overcoming current technological bottlenecks. Utility Model Content
[0004] Based on the above description, this utility model provides a laser soldering lens with an adjustable rectangular spot, which solves the significant defects of existing rectangular laser soldering lenses in terms of spot aspect ratio controllability, dual light source coordination, adjustment accuracy and optical path integration, and the inability to meet the high-efficiency and diversified needs of the electronics manufacturing industry for precision soldering.
[0005] This utility model is achieved through the following technical solution: An adjustable rectangular spot laser soldering lens includes a housing. A laser source is provided on one side of the top of the housing. The laser source is horizontally arranged and connected to a beam splitting unit at its output end. The beam splitting unit divides the laser source into a main light source and a secondary light source. Adjustment units are provided on the light source paths of both the main light source and the secondary light source. A focusing lens and a galvanometer are arranged sequentially and at intervals below the adjustment units. The main light source and the secondary light source pass through the adjustment units, the focusing lens, and the galvanometer in sequence and directly illuminate the surfaces of two workpieces respectively.
[0006] Based on the above technical solution, the present invention can be further improved as follows.
[0007] Furthermore, the beam splitting unit is configured as a polarization beam splitter, and the output ends of the main light source and the auxiliary light source are emitted at a 90° angle. A refracting mirror is also provided on the path of the main light source, and the light source paths of the main light source and the auxiliary light source both extend vertically downward.
[0008] Furthermore, the adjustment unit includes adjustment lenses. Two adjustment lenses are provided on the main light source path—an X-axis cylindrical lens and a Y-axis cylindrical lens. The X-axis cylindrical lens is arranged between the reflector and the beam splitter unit, and the Y-axis cylindrical lens is arranged between the reflector and the focusing lens. One adjustment lens is provided on the secondary light source path—an X-axis cylindrical lens or a Y-axis cylindrical lens. The X-axis cylindrical lens and the Y-axis cylindrical lens are arranged between the beam splitter unit and the focusing lens.
[0009] Furthermore, a beam expander and a light homogenizer are also arranged at intervals between the adjusting lens and the focusing lens on the light source path of the secondary light source.
[0010] Furthermore, each of the adjusting lenses has a frame along its outer edge, and the inner wall of the housing has a groove. The outer wall of the frame protrudes outward and is slidably inserted into the groove.
[0011] Furthermore, a lead screw is rotatably installed inside the slide groove, and the protrusion on the side wall of the frame is movably assembled with the lead screw through a threaded hole. A servo motor is also provided inside the housing, and the output end of the servo motor is connected to one end of the lead screw to drive the cylindrical lens to move in a directional manner.
[0012] Compared with the prior art, the technical solution of this application has the following beneficial technical effects: 1. This application improves upon existing rectangular laser soldering lenses by adopting a core design of "dual light sources + independent adjustment unit". The main light source, through the synergistic effect of the X-axis cylindrical lens and the Y-axis cylindrical lens, can achieve a wide range of aspect ratio adjustment from 1:5 to 5:1, covering all scenarios from slender leads to square pads (near 1:1 spot size). The auxiliary light source can be selectively configured with X-axis or Y-axis cylindrical lenses according to the specifications of the workpiece being soldered, achieving complementary or synchronous adjustment of the spot parameters with the main light source. This avoids the problem of frequent component replacement required by the existing "single light source fixed lens" technology, while eliminating disassembly and assembly errors, significantly improving production efficiency and soldering accuracy. 2. In this application, a servo motor is used to drive the lead screw to rotate, and the lens is moved in an directional manner through the thread transmission. The adjustment accuracy can reach ±0.01mm, realizing micron-level precise control of the beam aspect ratio; no manual adjustment is required, reducing operation error and adapting to the high-efficiency operation requirements of automated production lines in electronic manufacturing. Attached Figure Description
[0013] Figure 1 This is a schematic diagram of the light source path structure inside the lens in this embodiment; Figure 2 This is a schematic diagram of the adjustment unit in this embodiment; The components are: 1. Housing; 2. Laser source; 3. Beam splitting unit; 31. Reflector; 32. Main light source; 33. Secondary light source; 4. Adjustment unit; 41. Adjustment lens; 42. Frame; 43. Slide groove; 44. Lead screw; 45. Servo motor; 46. Beam expander; 47. Beam homogenizer; 5. Focusing lens; 6. Galvanometer. Detailed Implementation
[0014] To facilitate understanding of this application, a more complete description will be provided below with reference to the accompanying drawings, which illustrate embodiments of the present application. However, the present application can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided so that the disclosure of this application will be thorough and complete.
[0015] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the application.
[0016] Combination Figure 1 and Figure 2 As shown, a laser soldering lens with an adjustable rectangular spot includes: Housing 1 is the outer shell of the entire laser welding lens, used to assist in fixing the internal optical components; Laser source 2 is the core of energy input for the entire lens and can directly use existing laser emitters, such as fiber lasers, semiconductor lasers, etc. The beam splitting unit 3 is configured as a polarization beam splitter to split the laser source 2 into a main light source 32 and a secondary light source 33 with a fixed energy ratio. The main light source 32 is used for welding the workpiece, while the secondary light source 33 is used for preheating the workpiece before welding. Alternatively, dual-station welding can be achieved by dynamically adjusting the energy ratio of the main light source 32 and the secondary light source 33. The adjustment unit 4 is located inside the housing 1 and is used to adjust the welding spot on the main light source 32 without replacing the lens, which greatly improves the flexibility of lens adaptation. At the same time, it can also help adjust the spot size on the secondary light source 33 to ensure that the dual light sources can output spot shapes that are adapted to their respective workpieces. Focusing lens 5 and galvanometer 6 are used to concentrate the energy of the light spot on the main light source 32 and the secondary light source 33 to ensure that the light spot can reach the required energy density. Galvanometer 6 is used to realize the rapid deflection and positioning of the beam, which is suitable for welding multiple welding points and dual workpieces.
[0017] In the above structure, the main light source 32 and the auxiliary light source 33 on the beam splitter emit light at an angle of 90°, for example, the auxiliary light source 33 emitting light at an angle of 90°. Figure 1As shown, the main light source 32 extends horizontally, so a reflector 31 needs to be installed on the light path of the main light source 32 so that both the main light source 32 and the auxiliary light source 33 extend vertically downwards, with the auxiliary light source 33 in front and the main light source 32 behind—preheating first, then welding, thereby ensuring welding quality and processing efficiency.
[0018] The adjustment unit 4 includes an adjustment lens 41. Two adjustment lenses 41 are provided on the main light source 32, namely an X-axis cylindrical lens and a Y-axis cylindrical lens (both are aspherical cylindrical lenses, such as plano-concave aspherical cylindrical lenses, plano-convex aspherical cylindrical lenses, etc.). The X-axis cylindrical lens only produces a diverging effect in the "concave curvature direction" (X-axis) and has no refractive effect in the planar direction; the Y-axis cylindrical lens only produces a diverging effect in the "concave curvature direction" (Y-axis) and has no refractive effect in the planar direction. In the path of the main light source 32: the X-axis cylindrical lens is arranged between the reflector 31 and the beam splitter unit, and the Y-axis cylindrical lens is arranged between the reflector 31 and the focusing lens 5. The sole objective of the secondary light source 33 is to "uniformly preheat the material," rather than to "precisely match the rectangular size of the welding seam" as required by the primary light spot. Therefore, there is no need for bidirectional control of two sets of orthogonal cylindrical mirrors; a single cylindrical mirror can fulfill the core requirement. Consequently, in the path of the secondary light source 33, an X-axis cylindrical lens or a Y-axis cylindrical lens is arranged between the beam splitting unit 3 and the focusing mirror 5 to expand the light spot size.
[0019] Meanwhile, the secondary light source 33 is also equipped with a beam expander 46 and a light homogenizer 47. The cylindrical mirror, beam expander 46, and light homogenizer 47 work together to achieve a preheating spot with "wide beam size + low energy density + uniform energy distribution": the cylindrical mirror is responsible for beam expansion in one direction, the beam expander 46 supplements the size adjustment in another direction, and the light homogenizer 47 converts the Gaussian energy distribution into a flat-top distribution. The three together meet the core requirements of material preheating for the spot.
[0020] In this embodiment, both the main light source 32 and the secondary light source 33 must use aspherical cylindrical lenses, the core function of which is to reduce the impact of aberrations on the quality of the light spot. 1. Problems with spherical cylindrical mirrors: Because the curved surface is spherical, "spherical aberration" and "coma" will occur at the edge of the beam, resulting in blurred beam edges and uneven energy distribution (such as excessively high energy at the center and excessively low energy at the edges), which affects the welding quality (such as weak edge fusion). 2. Optimization of aspherical cylindrical mirrors: By designing "aspherical profiles" (such as parabolic or high-order polynomial surfaces), spherical aberrations can be accurately compensated, ensuring a consistent beam propagation path throughout the entire cross-section. The resulting rectangular beam has clear edges and energy uniformity can be improved to over 90% (compared to only 70%-80% for spherical mirrors), making it suitable for scenarios with high beam precision requirements, such as laser welding and cutting.
[0021] In addition, to facilitate the adjustment of the light spot size on the main light source 32, a frame 42 is provided on the outer edge of the adjusting lens 41. The outer side of the frame 42 protrudes outward. At the same time, a corresponding groove 43 is provided inside the housing 1, so that the protruding part is inserted into the groove 43. A lead screw 44 is also provided in the groove 43. The two ends of the lead screw 44 are rotatably connected to the side wall of the groove 43, and a threaded hole is reserved on the end face of the protruding part for transmission assembly with the lead screw 44. A servo motor 45 is also provided inside the housing 1. The servo motor 45 drives the lead screw 44 to rotate through the output end, thereby using the threaded hole to force the entire frame 42 to move along the direction of the groove 43, and finally realize the adjustment of the distance between the lens 41 and the light source.
[0022] In the above structure, the servo motor drives the lead screw 44 to rotate, which in turn drives the lens to move through the threaded transmission. The adjustment accuracy can reach ±0.01mm (corresponding to a spot size adjustment accuracy of ±0.005mm), which is much higher than the ±0.1mm error of the existing manual adjustment. This ensures precise control of the spot width-to-height ratio and avoids incomplete or over-welded welding caused by adjustment deviations. Furthermore, the tight sliding fit between the lens frame 42 and the slide groove 43 forms a rigid guiding constraint. When the welding equipment vibrates, the lens displacement is ≤0.5μm, which can effectively prevent spot shape drift and ensure the stability of spot parameters during long-term welding.
[0023] In the main light source 32: the X-axis cylindrical lens can move horizontally to change the convergence / divergence of the beam in the horizontal dimension, thereby adjusting the "width" of the light spot (e.g., shrinking from 0.1mm to 0.05mm, or expanding from 0.2mm to 0.5mm); the Y-axis cylindrical lens moves vertically to adjust the "height" of the light spot; the two work together to achieve an aspect ratio range of 1:5-5:1, covering different solder joint specifications such as slender pins (narrow and long light spot) and square pads (near 1:1 light spot), without the need to disassemble and replace lenses as in existing technologies, greatly improving the adaptability flexibility; In the secondary light source 33: depending on the difference in solder joints of the two workpieces, the X-axis or Y-axis cylindrical lens is selected for individual adjustment (e.g., when the main light source 32 is soldered with slender pins and the secondary light source 33 is soldered with wide pads, the secondary light source 33 expands the spot width through the X-axis lens) to ensure that the two light sources can output spot shapes that are adapted to their respective workpieces.
[0024] In addition, when two workpieces need to have the same spot size (such as synchronously welding chips of the same model), the cylindrical lenses of the main and auxiliary light sources 33 can be adjusted to ensure that the aspect ratio and size deviation of the two spot are ≤±1%, and the uniformity of energy distribution is consistent (in conjunction with the beam expander 46 + light homogenizer 47), thus avoiding the uneven solder joint quality caused by the "large difference between the main and auxiliary light spots" in the existing dual light source scheme. When two workpieces require different spot specifications (such as the main light source 32 welding pins and the auxiliary light source 33 welding pads), the adjustment unit 4 can independently control the parameters of the two, without the need to add additional optical path components, simplifying the lens structure while meeting the differentiated welding requirements.
[0025] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the technical solutions of the embodiments of this utility model.
Claims
1. A laser soldering lens with adjustable rectangular spot, characterized in that, Includes a housing (1), on one side of the top of the housing (1) is a laser source (2), the laser source (2) is arranged horizontally and connected to a beam splitting unit (3) at the output end, the beam splitting unit (3) divides the laser source (2) into a main light source (32) and a secondary light source (33), and adjustment units (4) are provided on the light source paths of the main light source (32) and the secondary light source (33), and a focusing lens (5) and a galvanometer (6) are arranged in sequence below the adjustment unit (4). The main light source (32) and the secondary light source (33) pass through the adjustment unit (4), the focusing lens (5) and the galvanometer (6) in sequence and shine directly on the surfaces of the two workpieces respectively.
2. The laser soldering lens with adjustable rectangular spot as described in claim 1, characterized in that, The beam splitting unit (3) is configured as a polarization beam splitter and the output ends of the main light source (32) and the auxiliary light source (33) are emitted at a 90° angle. A refracting mirror is also provided on the path of the main light source (32) and the light source paths of the main light source (32) and the auxiliary light source (33) are both extended vertically downward.
3. The laser soldering lens with adjustable rectangular spot as described in claim 2, characterized in that, The adjustment unit (4) includes an adjustment lens (41). Two adjustment lenses (41) are provided on the path of the main light source (32) - an X-axis cylindrical lens and a Y-axis cylindrical lens. The X-axis cylindrical lens is arranged between the reflector (31) and the beam splitting unit, and the Y-axis cylindrical lens is arranged between the reflector (31) and the focusing lens (5). The adjustment lens (41) on the path of the secondary light source (33) is provided as one - an X-axis cylindrical lens or a Y-axis cylindrical lens. The X-axis cylindrical lens and the Y-axis cylindrical lens are arranged between the beam splitting unit (3) and the focusing lens (5).
4. The laser soldering lens with adjustable rectangular spot as described in claim 3, characterized in that, Located on the light source path of the secondary light source (33), a beam expander (46) and a light homogenizer (47) are also arranged at intervals between the adjusting lens (41) and the focusing lens (5).
5. The adjustable rectangular spot laser soldering lens according to claim 4, wherein, Each of the adjustment lenses (41) has a frame (42) on its outer edge, and a groove (43) is provided on the inner side wall of the housing (1). The outer wall of the frame (42) protrudes outward and is slidably inserted into the groove (43).
6. The adjustable rectangular spot laser soldering lens according to claim 5, wherein, A lead screw (44) is rotatably installed inside the slide (43). The protrusion on the side wall of the frame (42) is movably assembled with the lead screw (44) through a threaded hole. A servo motor (45) is also provided inside the housing (1). The output end of the servo motor (45) is connected to one end of the lead screw (44) and used to drive the cylindrical lens to move in a directional manner.