Edge Banding Laser Module with Direct Emission and Microlens Array
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Solution Overview
Problem
Conventional laser systems for activating adhesive layers on edge bands have low efficiency due to energy losses from beam guiding optics, requiring complex beam deflection devices and resulting in inefficient power delivery for edge band application.
Innovation Solution
A device with semiconductor radiation sources, such as VCSEL units, generates laser radiation directly in the feed area between the edge band and the workpiece, eliminating the need for beam deflection devices and using microlenses for parallel power distribution, along with a protective pane, suction device, and absorber elements for improved efficiency and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional laser systems with beam guiding optics are used to activate the adhesive layer, then the laser beam can be directed onto the edge band layer, but energy losses occur due to optical components resulting in low efficiency
Solution Approach 1:
The invention extracts and eliminates the beam guiding optics from the system by repositioning the laser source directly into the feed area where the edge band is fed. This removes the intermediate optical components (prisms, mirrors) that caused energy losses, directly resolving the contradiction between energy efficiency and device complexity.
Solution Approach 2:
The invention introduces a beam shaping element as an intermediary component between the laser source and the edge band layer. This mediator shapes and directs the laser beam locally without requiring complex beam guiding optics, maintaining energy efficiency while achieving precise activation of the adhesive layer.
2Power
If the laser beam is generated remotely and directed by optics in the feed area, then activation can be performed, but overall efficiency is reduced due to power losses from optical components
Solution Approach 1:
The invention extracts the laser generation function from the remote location and places it directly in the feed area. This eliminates the power transmission path through optical components, removing the source of energy losses and improving overall power delivery efficiency to the adhesive layer.
Solution Approach 2:
The invention segments the laser beam into multiple parallel beams using a beam shaping element with multiple emission zones. This segmentation allows direct power delivery to different areas of the adhesive layer simultaneously, improving power distribution efficiency without requiring complex optical steering mechanisms.
3Ease of operation
If beam deflection devices such as prisms are used to direct the laser beam, then the beam can reach the edge band, but the device becomes more complex and efficiency decreases
Solution Approach 1:
The invention removes beam deflection devices from the system by generating the laser beam directly at the required location in the feed area. The beam shaping element provides inherent direction control through its structured emission zones, eliminating the need for separate deflection mechanisms and simplifying the overall device.
Solution Approach 2:
The invention replaces the mechanical beam deflection system (prisms, mirrors) with a beam shaping element that uses optical segmentation and direct emission geometry to control beam direction. This substitution eliminates moving parts and complex mechanical adjustments while maintaining precise beam control.
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 enhances energy efficiency and protects the radiation module by reducing optical component contamination and mechanical damage, ensuring consistent activation of the adhesive layer with precise power control and temperature monitoring.
Implementation Method 1
The individual units emitting laser radiation preferably have dimensions of only a few micrometers. Although the individual units can only emit a very low laser power, due to the large number of units that can be arranged on a radiation element or on a radiation module, a power can surprisingly be generated overall
Implementation Method 2
In order in particular to ensure that the emitted laser power is parallel, optical elements can be arranged between the units emitting laser radiation and the layer to be activated. These are preferably microlenses
Implementation Method 3
This adhesive layer or adhesion-promoting layer is, in particular, a heat-activatable layer, for example a plastic layer, which is melted or melted on by the input of radiation in order to form an adhesive layer or adhesion-promoting layer
Data Source
Figure 1
Figure 1a
Figure 1b
AI summary
The device (1) for applying an edge band (4) to a narrow side (3) of a workpiece, in particular made of wood or a wood substitute material, comprises a radiation source for activating an adhesive layer or adhesion-promoting layer. The radiation source is a radiation module (8) with a plurality of laser radiation-emitting radiation elements (10).