Laser Beam Shaping for Precise Soldering Temperature Control
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Solution Overview
Problem
Laser soldering systems face challenges in efficiently soldering elements with different processing temperatures due to overheating and uneven heating, which can result in damage to components or inadequate solder melting.
Innovation Solution
A laser soldering system that includes a laser source module, a polarization adjusting assembly, a temperature sensor, and a controller. The system splits the laser beam into a Gaussian beam and a ring-shaped beam, allowing for precise temperature control and power adjustment based on real-time temperature monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single Gaussian laser beam is used for soldering, then the laser can be simple and easy to control, but it causes overheating damage to elements below the gap between pin and soldering pad
Solution Approach 1:
The patent divides the single Gaussian laser beam into two separate beams: a Gaussian beam for illuminating the pin and a ring-shaped beam for illuminating the soldering pad. This segmentation allows independent control of each beam's power and shape, preventing the overheating damage caused by concentrated Gaussian energy while maintaining simple overall system control.
2Device complexity
If laser power ratio between pin and soldering pad is not appropriately adjusted, then the control system remains simple, but it causes rough solder melting or pin damage due to insufficient or excessive heating
Solution Approach 1:
The patent applies different power ratios and beam shapes to different regions: the Gaussian beam provides concentrated power for the pin while the ring-shaped beam distributes power for the soldering pad. The polarization adjusting assembly independently controls the power ratio of each beam, ensuring each element receives appropriate localized heating for high-quality soldering.
3Manufacturing precision
If the laser beam is shaped to illuminate different regions with different power distributions, then temperature control precision improves, but the optical system complexity increases
Solution Approach 1:
The patent introduces a polarization adjusting assembly as an intermediary component between the laser source and the workpiece. This assembly uses polarization beam splitters and wave plates to control the power ratio and shape of the laser beams, achieving precise temperature control while keeping the overall system structure manageable through modular optical components.
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 system effectively prevents overheating and ensures precise temperature control, improving soldering efficiency and yield by adjusting the power ratio of the laser beams in real-time.
Implementation Method 1
The polarization elements are configured to split the laser beam into a Gaussian beam and a ring-shaped beam
Implementation Method 2
the axicon lens assembly is configured to form the ring-shaped beam
Implementation Method 3
The temperature sensor is configured to monitor temperatures of the first element and a temperature of the second element
Implementation Method 4
The Gaussian beam illuminates the first element, and the ring-shaped beam is illuminates the second element
Implementation Method 5
The laser source module is configured to emit a laser beam
Data Source
AI summary
A laser soldering system includes a laser source module, a polarization adjusting assembly, a temperature sensor, and a controller. The laser source module is configured to emit a laser beam. The polarization adjusting assembly includes a plurality of polarization elements and at least one stepping motor. The polarization elements are configured to split the laser beam into a Gaussian beam and a ring-shaped beam. The Gaussian beam illuminates the first element, and the ring-shaped beam is illuminates the second element. The stepping motor is configured to adjust a size of the ring-shaped beam. The temperature sensor is configured to monitor temperatures of the first element and a temperature of the second element. The controller is electrically connected to the temperature sensor, the laser source module, and the polarization adjusting assembly.