Laser Welding Beam Splitting for Ghost Beam Reduction
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Solution Overview
Problem
Current laser welding systems for electronic devices, such as batteries, face issues with high energy consumption and the production of ghost beams, which can cause undesirable effects like damage to internal components due to inefficient energy distribution and beam patterns.
Innovation Solution
The method involves arranging overlapping heat source points with linear profiles at oblique angles to reduce energy consumption and ghost beam production, using a laser welding system with beam modifying means like diffractive optical elements to split the laser beam into fewer output beams, and directing these beams along a weld line to form specific patterns that minimize internal exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a high power laser oscillator is used to create five or more welding beams in a symmetric cross shape, then welding coverage and seal quality are improved, but energy consumption and device cost increase significantly
Solution Approach 1:
The patent divides the welding beam into multiple separate beams (typically 3-5 beams) that are distributed in a specific pattern rather than using a single high-power beam or a symmetric cross pattern. This segmentation allows the laser energy to be distributed more efficiently across the weld area, reducing the peak power requirement while maintaining effective welding coverage and seal quality.
Solution Approach 2:
The patent employs an asymmetric distribution of multiple welding beams instead of a symmetric cross pattern. The beams are positioned at specific angles and locations that are optimized for welding performance, creating an asymmetric pattern that reduces ghost beam interference and improves energy utilization efficiency while maintaining reliable sealing.
2Area of stationary object
If a symmetric cross pattern with five or more heat source points is used, then welding coverage is improved, but ghost beam production increases causing undesirable effects on internal components
Solution Approach 1:
The patent uses an asymmetric arrangement of multiple welding beams instead of a symmetric cross pattern. This asymmetric configuration is specifically designed to minimize ghost beam generation and interference patterns that could otherwise damage internal battery components, while still providing adequate welding coverage area through optimized beam positioning and angles.
Solution Approach 2:
The patent applies different characteristics to different regions of the welding pattern. The primary beams are positioned and configured for effective welding, while the overall asymmetric pattern is designed to minimize ghost beam effects in specific areas. This local optimization ensures both welding coverage and protection of internal components from harmful ghost beam effects.
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 reduces energy consumption, enhances welding accuracy, and decreases the risk of undesirable effects on internal parts, achieving a more efficient and precise welding process.
Implementation Method 1
a laser beam is used to create five or more heat source points in a symmetric cross shape using optical elements (e.g., diffractive optical elements)
Implementation Method 2
A laser source is provided and configured to produce a laser beam
Implementation Method 3
irradiating a portion of a target with the first and second collections of heat source points
Data Source
Figure 1A~2A
Figure 2B~2D
Figure 3A~4D
AI summary
A method of laser welding is provided. The method includes arranging at least one heat source point from a first collection of heat source points so as to overlap at least a portion of at least one heat source point from a second collection of heat source points, irradiating a portion of a target (2) with the first and second collections of heat source points, the heat source points maintaining a linear profile within their respective collection, and directing the at least two collections of heat source points in a travel direction along a weld line, each linear profile maintaining an oblique angle relative to the travel direction.