Laser Nozzle Coolant Channel Layout for High-Power Heat Control

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Solution Overview

Problem

Laser processing systems face challenges in efficiently cooling nozzles at higher power levels, leading to heat absorption issues and potential safety concerns, while existing cooling methods often compromise cut quality or introduce complexities.

Innovation Solution

The design incorporates fluid passages and carefully oriented auxiliary passages within the nozzle to enhance cooling, with a secondary fluid flow that impinges on a conduit to redirect the coolant toward the nozzle's exterior surface, increasing exposure to coolant flows and improving thermal regulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If higher power laser beams are used to process thicker materials, then processing capability is improved, but heat absorption by the nozzle increases leading to temperature exceeding safety limits

Engineering Contradiction:

Improvelaser beam powerVSAvoidnozzle temperature

Core Design Contradiction:

PowerVSTemperature

Solution Approach 1:

The nozzle is divided into multiple thermal zones with separate cooling channels positioned at different locations to address heat absorption in specific high-risk areas such as the beam path walls and flange regions, allowing targeted cooling without compromising overall nozzle performance

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A coolant fluid is introduced as an intermediary substance to absorb excess heat from the nozzle walls through thermal conduction and convection, preventing heat transfer to the laser beam and workpiece while maintaining nozzle structural integrity and safety temperature limits

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If coolant channels are added to cool the nozzle, then temperature control is improved, but cooling fluid can be entrained into the laser beam resulting in substandard cut qualities

Engineering Contradiction:

Improvenozzle temperatureVSAvoidcut quality

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The cooling fluid flow path is extracted and separated from the laser beam path through dedicated cooling channels positioned in the nozzle walls and flange regions, ensuring that coolant remains confined to cooling zones and does not contaminate the cutting zone, thereby maintaining cut quality while achieving effective temperature control

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Cooling channels are strategically positioned in specific high-heat zones such as the beam path walls and flange regions where heat absorption is most critical, allowing localized cooling without affecting the overall cutting process or introducing coolant into the laser beam path

Inventive Principle:

Principle #3Local quality

3Temperature

If water cooling systems are implemented, then cooling effectiveness is improved, but system complexity increases due to leak-free delivery requirements and potential rusting issues

Engineering Contradiction:

Improvenozzle temperatureVSAvoidcooling system complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The nozzle is designed with integrated cooling channels that can be easily manufactured using additive manufacturing or other modern fabrication techniques, allowing the nozzle to be replaced if needed without requiring complex external cooling systems, pumps, or hoses, thereby reducing overall system complexity while maintaining effective cooling

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The cooling function is merged with the nozzle structure itself by integrating cooling channels directly into the nozzle body and flange regions, eliminating the need for separate external cooling systems and reducing the number of potential leak points and maintenance requirements

Inventive Principle:

Principle #5Merging (Combining)

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 approach effectively maintains nozzle life and safety by enhancing cooling efficiency, reducing heat absorption, and preserving cut quality by isolating the coolant flow from the primary cutting fluid.

Implementation Method 1

flow a secondary fluid through the nozzle body in a first direction to cool the nozzle body

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 2

impinge on a surface of the at least one conduit that is proximate the primary passage

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20250073814A1Directed coolant flows in a nozzle for a laser processing system

Publication Date: 2025.03.06 HYPERTHERM INC

AI summary

A nozzle for a laser processing system is provided. A primary passage extends between the proximal end and the distal end of the nozzle body along a central longitudinal axis. At least one auxiliary passage is located within the body of the nozzle adjacent to the primary passage while substantially fluidly isolated from the primary passage. At least one conduit is located proximate the distal end of the body and in fluid communication with the at least one auxiliary passage. The at least one auxiliary passage is configured to flow a secondary fluid through the body of the nozzle in a first direction to impinge on a surface of the at least one conduit that is proximate the primary passage. The at least one conduit is configured to redirect the secondary fluid toward an exterior surface of the body in a second direction.