Beam Splitter Layout for Small-Spot Laser Brazing Preheating
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Solution Overview
Problem
Existing laser brazing and welding processes face challenges in creating stable, small heating spots for pre-heating workpieces without interfering with the brazing/welding wire, as existing arrangements fail to achieve efficient light coupling into secondary fibers due to low brilliance.
Innovation Solution
A laser processing head with a collimator, beam splitter, and secondary output is used to split laser light into a main and secondary beam, utilizing an anti-reflective and high-reflective portion to direct collimated light effectively into a main laser beam for brazing/welding and a secondary beam for pre-heating, respectively, with a focusing lens and waveguide for precise delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a second laser beam is derived from the main laser beam using a beam splitter to create small heating spots, then pre-heating efficiency is improved, but the brilliance of light coupled into the second fiber is insufficient leading to large spot sizes
Solution Approach 1:
The patent segments the laser beam into multiple paths using a beam splitter with different reflective portions. The first beam path directs light through the first optical fiber for main brazing/welding, while the second beam path directs light through the second optical fiber for pre-heating. This segmentation allows independent optimization of each beam path for its specific function, enabling small heating spots in the pre-heating path without compromising the main beam quality.
Solution Approach 2:
The beam splitter has different reflective properties in different regions: a first reflective portion with high reflectivity for directing main beam light, and a second reflective portion with lower reflectivity for directing pre-heating beam light. This local quality variation allows the system to optimize light distribution - the second path receives sufficient light intensity for efficient pre-heating while maintaining small spot size through proper optical coupling.
2Object-affected harmful factors
If the laser light for pre-heating is passed close to the wire to avoid interference, then wire interference is reduced, but the pre-heating becomes unstable leading to unstable joining process
Solution Approach 1:
By segmenting the laser beam into separate paths using the beam splitter, the patent creates independent optical channels for main brazing and pre-heating functions. The second beam path for pre-heating is spatially separated from the wire area, eliminating wire interference while maintaining stable pre-heating conditions through dedicated optical fiber delivery and focusing optics.
3Ease of operation
If an independent laser source is used for pre-heating, then pre-heating control is improved, but device complexity increases
Solution Approach 1:
The patent segments a single laser source into multiple functional beams using a beam splitter with region-specific reflective portions. This allows independent control of main brazing and pre-heating functions through separate optical paths and fiber delivery systems, achieving the control benefits of multiple sources while maintaining the simplicity of a single laser source.
Solution Approach 2:
A single laser source performs multiple functions by generating different beam paths through the beam splitter. The first path provides main brazing/welding energy, while the second path provides pre-heating energy. This multi-functionality eliminates the need for separate laser sources while maintaining independent control capabilities for each process function.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration allows for precise, stable pre-heating of workpieces and efficient removal of surface coatings, enhancing the quality of the brazing/welding process by maintaining control over the heating spots and reducing interference with the brazing wire.
Implementation Method 1
The collimator is disposed in an optical axis of the laser light and is configured to collimate the laser light into collimated light
Implementation Method 2
The beam splitter is disposed in the collimated light and has at least two portions. The at least two portions comprise an anti-reflective portion and a high-reflective portion. The beam splitter is configured to split the collimated light into first light from a first of the at least two portions and into second light from a second of the at least two portions
Data Source
AI summary
A laser processing head can be used for joining (e.g., welding, brazing, soldering, etc.) workpieces. A collimator collimates laser light, which passes to a beam splitter. The beam splitter has anti-reflective and high-reflective coatings on peripheral and inner areas of the beam splitter. The beam splitter splits the collimated light into central or inner light from the inner area and peripheral light from the peripheral area. A main output in communication with the beam splitter directs at least the peripheral light into a main beam toward the workpieces. For example, a cable can feed a brazing wire adjacent the main beam for brazing the workpieces together. Meanwhile, a secondary output in communication with the beam splitter directs at least the central light into a secondary beam, which can be used to pre-heat the workpiece, post-heat the workpiece, or remove any surface coating from the workpiece.