Common Beam Path Laser Joining for Coated Sheet Surfaces
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Solution Overview
Problem
Conventional laser-based joining devices face challenges in reliably joining coated components, such as hot-dip galvanized sheet metal, due to issues like splashes, pores, and a rough weld surface, which affect the esthetic quality and process stability.
Innovation Solution
A joining device that uses a common beam path to focus first and second laser radiations from separate sources, where the first laser radiation is used for material bonding and the second for surface pretreatment, such as ablation or melting of coatings, to improve the joining process's reliability and esthetic quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate beam paths and optical systems are used for each laser radiation source, then the laser radiations can be focused independently into the joining zone, but the installation effort and device complexity increase
Solution Approach 1:
The patent combines multiple laser beam paths into a single common beam path using a beam combining optical system. This allows multiple laser radiations from different sources to be focused through the same optical system and beam path, reducing the number of separate optical systems and beam paths needed, thereby decreasing installation effort and device complexity while maintaining the ability to independently focus each laser radiation
Solution Approach 2:
The common beam path and optical system serve multiple functions by handling and focusing multiple different laser radiations simultaneously. The single optical system is designed to accommodate and focus various laser wavelengths and beam characteristics, making it a multi-functional system that reduces overall device complexity while maintaining precise control over each laser source
2Strength
If laser radiation is used for joining coated components, then material bonding can be achieved, but surface defects like splashes, pores, and rough weld surfaces occur
Solution Approach 1:
The patent applies preliminary surface treatment to coated components before laser joining by using one or more laser radiations to preheat, preheat and melt, or ablate the coating in the joining zone. This preliminary action modifies the coating surface properties ahead of time, creating a more favorable surface for subsequent laser joining, thereby reducing surface defects like splashes, pores, and roughness while maintaining strong material bonding
Solution Approach 2:
The patent changes the physical and chemical parameters of the coating surface through laser-based preliminary treatment. By controlling laser parameters such as power, duration, and wavelength, the coating undergoes controlled heating, melting, or ablation that modifies its surface properties, making it more compatible with the base material and reducing harmful surface effects during the joining process
3Reliability
If multiple laser radiations are applied to the joining zone, then surface pretreatment and material bonding can be achieved, but the number of laser radiation sources and optical systems increases
Solution Approach 1:
The patent merges multiple laser beam paths into a single common beam path using a beam combining optical system. This allows multiple laser radiations from different sources to be focused through the same optical system and beam path, reducing the number of separate optical systems and beam paths needed, thereby decreasing installation effort and device complexity while maintaining the ability to independently focus each laser radiation
Solution Approach 2:
The common beam path and optical system serve multiple functions by handling and focusing multiple different laser radiations simultaneously. The single optical system is designed to accommodate and focus various laser wavelengths and beam characteristics, making it a multi-functional system that reduces overall device complexity while maintaining precise control over each laser source
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 approach enhances the esthetic quality of the joining seam, increases the solder's filling volume and bonding length, and reduces sensitivity to disturbance variables like laser power fluctuations, enabling reliable laser-based joining of coated components.
Implementation Method 1
the laser radiation of a first laser radiation source is used to effect material bonding of two components in a joining zone
Implementation Method 2
the laser radiation of a second laser radiation source is used to effect preheating of the two components as a joining pretreatment
Implementation Method 3
The focusing device is coupled to the first and second radiation guides and are configured to focus the first laser radiation and the second laser radiation at a distance from each other into a joining zone
Data Source
AI summary
A joining device and method for laser-based joining of two components includes a first laser radiation source, a first radiation guide connected to the first radiation source to couple first laser radiation into the first radiation guide, a second laser radiation source, at least one second radiation guide connected to the second radiation source to couple second laser radiation into the second radiation guide, and a focusing device coupled to the laser radiations and focusing them at a distance from each other into a joining zone of the components. To reduce installation effort, the focusing device focuses the first and second laser radiations through a common beam path and a coupling device is connected on its input side to the first and second radiation guides and on its output side to the focusing device. The coupling device couples the first and second laser radiations into the common beam path.