Cross Jet Laser Welding Nozzle with Air Knife Cooling
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Solution Overview
Problem
Conventional laser welding systems are bulky due to the need for separate airflow and gas shielding systems, which complicates the integration of an air knife for protecting the laser optic and providing active cooling without interfering with the process gas delivery.
Innovation Solution
A compact nozzle design that integrates an air knife for protecting the laser optic and coaxially supplied process shield gas with active air cooling, using a single nozzle that includes a mounting interface, air knife section, and separate gas fittings for air and process gas, ensuring the air knife flow does not contaminate the process gas and allows for independent control of airflow and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate feed systems and gas shrouds are installed to accommodate airflow for optic protection and process gas delivery, then the laser welding system can effectively protect the laser optic and provide process gas shielding, but the system becomes large and bulky, incompatible with small movable laser processing head systems
Solution Approach 1:
The patent combines the air knife section and process gas shield section into a single integrated nozzle body. The air knife section delivers airflow for optic protection and active cooling, while the process gas shield section delivers process gas for weld zone shielding. Both functions are merged into one compact nozzle structure, eliminating the need for separate feed systems and gas shrouds, thus reducing overall system size and bulk while maintaining both protective functions.
Solution Approach 2:
The integrated nozzle serves multiple functions simultaneously: it acts as an air knife for optic protection, provides active cooling through directed airflow, delivers process gas for weld shielding, and maintains a compact form factor suitable for movable laser processing heads. This multi-functionality resolves the contradiction by consolidating what would traditionally require separate systems into a single universal component.
2Temperature
If air flow is directed through the nozzle for direct cooling of the laser, then active cooling is achieved, but the air knife flow may contaminate the process gas if not properly isolated
Solution Approach 1:
The nozzle is segmented into distinct functional sections: an air knife section for delivering cooling airflow and a process gas shield section for delivering process gas. These sections are isolated from each other within the nozzle structure, allowing independent control of airflow and process gas flow. The segmentation ensures that the air knife flow for cooling does not mix with or contaminate the process gas, maintaining both cooling effectiveness and gas purity.
Solution Approach 2:
The nozzle structure itself acts as an intermediary that separates and directs different fluid streams. The internal geometry of the integrated nozzle serves as a mediator between the air knife flow and process gas flow, ensuring they remain isolated while both functions are performed within the same component. This intermediary structure prevents contamination while enabling active cooling.
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
The solution provides a compact and efficient laser welding system that effectively protects the laser optic from plasma and spatter while maintaining a contamination-free process gas delivery, enhancing the maneuverability and accessibility of the laser cutter and reducing turbulence, thus improving weld quality.
Implementation Method 1
an air knife section (14) positioned adjacent the mounting interface and the optical output of the laser so that the air knife flow can protect the optic from plasma and spatter damage
Implementation Method 2
the air flow in the air knife is directed through the nozzle for direct cooling
Implementation Method 3
Adjacent the air knife is the process gas shield that is isolated from the air knife such that the process gas is not contaminated by flow from the air knife
Data Source
AI summary
A compact nozzle for laser welding is provided that includes an air knife cross-jet to protect the laser optic, coaxially supplied process shield gas and active air cooling in a singular and compact nozzle. Generally, the nozzle includes a mounting interface at a first end to connect to the laser processing device. An air knife section is positioned adjacent the mounting interface and the optical output of the laser so that the air knife flow can protect the optic from plasma and spatter damage. Further the air flow in the air knife is directed through the nozzle for direct cooling. Adjacent the air knife is the process gas shield that is isolated from the air knife such that the process gas is not contaminated by flow from the air knife.