Multi-Zone Laser Beam Shaping for Stronger Glass-Metal Welding
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Solution Overview
Problem
Conventional glass and metal bonding technologies face challenges such as high energy consumption, adhesive deterioration, and reduced bonding strength due to environmental changes and heat generation from electronic components.
Innovation Solution
A laser beam shaping device and laser processing system that uses a multi-zone structure lens to divide a light source into multiple discrete sets of light beams, projecting them obliquely onto a target material to form an interlocking welding structure without adhesives, thereby increasing contact area and welding strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive bonding method is used to join metal and glass, then the bonding process is simple, but the adhesive deteriorates over time and bonding strength is reduced
Solution Approach 1:
The invention extracts and eliminates the adhesive layer from the bonding system, replacing it with direct laser welding between metal and glass substrates. This removes the source of deterioration while maintaining bonding functionality through metallurgical and glass-to-metal bonds created by laser heating.
Solution Approach 2:
The invention replaces the mechanical adhesive bonding system with a thermal laser welding system. The laser beam provides localized heating to create strong metallurgical bonds between metal and glass, substituting the chemical adhesive mechanism with a thermal processing mechanism that produces superior bond strength and environmental stability.
2Ease of manufacture
If adhesive is used for bonding, then initial bonding is achieved, but adhesive deteriorates when exposed to moisture and environmental changes
Solution Approach 1:
The adhesive layer is completely removed from the bonding structure, eliminating its vulnerability to moisture and environmental degradation. The laser welding process creates direct bonds between substrates that are inherently resistant to environmental factors.
Solution Approach 2:
The invention changes the bonding mechanism from chemical adhesive bonding to thermal laser welding. This parameter change transforms the bond interface from an organic adhesive layer susceptible to environmental changes into a direct substrate-to-substrate bond with superior environmental stability.
3Ease of manufacture
If conventional bonding methods are used, then assembly is simple, but electronic components fail due to heat generation and adhesive volatilization
Solution Approach 1:
The adhesive layer is removed from the bonding system, eliminating it as a source of volatilization and pollution. The laser welding process directly bonds components without requiring organic adhesives that can decompose under heat from electronic components.
Solution Approach 2:
The invention converts the harmful effect of heat generation from electronic components into a beneficial effect by using laser heating to create strong metallurgical bonds. The same thermal energy that would cause adhesive degradation is harnessed to create robust welds between metal and glass substrates.
4Device complexity
If single light beam is used for laser welding, then processing is simple, but contact area at interface is limited and welding strength is insufficient
Solution Approach 1:
The laser beam is segmented into multiple discrete beams using a multi-zone structure lens. This segmentation allows each beam to target specific regions at the interface between substrates, increasing the total contact area and creating multiple bond zones that collectively enhance welding strength.
Solution Approach 2:
The invention transitions from a single-point laser welding approach to a multi-point distributed welding approach. By projecting multiple beams at oblique angles onto the interface, the bonding process extends across multiple spatial dimensions, increasing the effective contact area and creating a more robust three-dimensional bond structure.
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 enhances the bonding strength between glass and metal materials by increasing the contact area at the interface and improving the durability of the bond, while eliminating the need for adhesives and reducing energy consumption.
Implementation Method 1
The light source passing through the refractive structure deviates away from the optical axis and leaves the lens body via the emission plane. The light source passing through the lens body is divided into N sets of light beams
Implementation Method 2
The focusing lens is used for receiving the N sets of light beams from the multi-zone structure lens. After the N sets of light beams penetrate through the focusing lens, N set of incident beams are formed to project the interface of the first material and the second material in an oblique inward manner
Implementation Method 3
a laser processing system that uses a multi-zone structure lens to divide a light source into multiple discrete sets of light beams, projecting them obliquely onto a target material to form an interlocking welding structure
Data Source
AI summary
A laser beam shaping device includes a multi-zone structure lens and a focusing lens. The multi-zone structure lens includes a lens body and a refractive structure. The lens body has an incident plane and an emission plane, and one of the incident plane and the emission plane is furnished with the refractive structure. The light source passing through the refractive structure deviates and leaves the lens body via the emission plane. The light source passing through the lens body is divided into N sets of light beams. After the N sets of light beams penetrate through the focusing lens, N set of incident beams are formed to project the interface of the first material and the second material in an oblique inward manner with respect to the optical axis of the focusing lens. In additional, a laser processing system and a laser interlocking welding structure respectively are also provided.