Laser Mixing Nozzle for Gas Flow Profile Control
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Solution Overview
Problem
Laser processing systems face challenges in controlling the pressure and velocity flow profiles of gas streams, leading to suboptimal cut quality and increased operating costs due to the need for high-pressure inert gases like nitrogen and argon, which can cause oxidation and require costly equipment maintenance.
Innovation Solution
A nozzle design that passively mixes primary and secondary gases within the nozzle, creating multiple fluid flow passages to control pressure and velocity profiles, allowing for improved cut quality at lower operating costs by using less expensive gases like air.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If nitrogen or argon are used in the gas stream to prevent oxidation, then cut quality is improved, but operating cost increases due to high pressure and flow rate requirements
Solution Approach 1:
The gas stream is segmented into multiple flow passages with different pressure zones. The nozzle divides the gas delivery system into a first flow passage for higher pressure gas and a second flow passage for lower pressure gas, allowing selective use of expensive inert gases only where oxidation prevention is critical while using cheaper gases in other regions.
Solution Approach 2:
Different regions of the gas stream are assigned different gas compositions and pressures based on local requirements. The peripheral region receives high-pressure inert gas for oxidation prevention at the cut zone, while the central region can use lower-pressure or different composition gas, optimizing both cut quality and operating cost.
2Manufacturing precision
If the peripheral and central regions are fed with different pressures to alter flow profile, then control over pressure and velocity profiles is improved, but backflow occurs creating spatter that damages the nozzle
Solution Approach 1:
The nozzle incorporates dynamic pressure balancing through multiple flow passages that adapt to operating conditions. The system dynamically adjusts pressure distribution between peripheral and central regions while maintaining forward flow dominance, preventing backflow conditions that would cause spatter and damage.
Solution Approach 2:
A pressure balancing mechanism acts as an intermediary between the different pressure zones. The nozzle design includes intermediate flow paths and pressure regulation features that mediate between the high-pressure peripheral region and lower-pressure central region, preventing direct backflow while maintaining the beneficial pressure differential for flow profile control.
3Device complexity
If a single plenum feeds both peripheral and central regions, then device complexity is reduced, but control over differential pressure and flow profiles is minimized
Solution Approach 1:
The single plenum is segmented into multiple flow passages within the nozzle body. Rather than one unified flow path, the nozzle contains separate first and second flow passages that divide the gas delivery into distinct channels, enabling differential pressure and flow rate control to different regions while maintaining a relatively simple overall nozzle structure.
Solution Approach 2:
The nozzle design achieves multi-functionality by incorporating multiple flow passages that can deliver different gas compositions and pressures simultaneously. The same nozzle structure can adapt to different operating requirements by adjusting flow distribution between passages, providing both structural simplicity and operational flexibility.
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 nozzle design enhances control over cutting variables, reduces material oxidation, and decreases operating costs by minimizing the use of expensive inert gases, while maintaining cut quality and extending the lifespan of laser consumables.
Implementation Method 1
A distal portion of the at least one auxiliary passage diverts into two fluid flow passages includes a first fluid flow passage configured to direct a first portion of an auxiliary fluid axially forward toward the distal end of the nozzle body to substantially shroud the laser beam emerging from the primary passage and a second fluid flow passage configured to direct a second portion of the auxiliary fluid radially inward to mix with the primary fluid in the primary passage
Implementation Method 2
The nozzle comprises a primary passage disposed in a body of the nozzle. The primary passage is configured to direct a laser beam and a primary fluid from a proximal end of the body to a distal end of the body to process the workpiece
Data Source
AI summary
A nozzle for a laser processing head is provided. The nozzle includes a primary passage disposed in a body of the nozzle. The primary passage is configured to direct a laser beam and a primary fluid from a proximal end of the body to a distal end of the body. The nozzle also includes a set of at least one auxiliary passage disposed in the body of the nozzle and radially offset from a longitudinal axis of the primary passage. A distal portion of the auxiliary passage diverts into two fluid flow passages including (i) a first fluid flow passage configured to direct a first portion of an auxiliary fluid axially forward toward the distal end of the nozzle body, and (ii) a second fluid flow passage configured to direct a second portion of the auxiliary fluid radially inward to mix with the primary fluid in the primary passage.