Abstract:
A laser welding lens assembly for welding a first article to a second article at a weld zone includes a laser source outputting a laser beam. An optical fiber is operably coupled to the laser source to receive and transmit the laser beam. A lens is then positioned to receive the laser beam from the optical fiber. The lens includes a contoured face that is shaped to refract the laser beam to produce a generally uniform temperature profile across the weld zone.

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to welding and, more particularly, relates to an improved method and apparatus for producing uniform welding. 
     BACKGROUND OF THE INVENTION 
     Laser welding is commonly used to join plastic or resinous parts, such as automobile thermoplastic parts, at a welding zone. An example of such use of lasers can be found in U.S. Pat. No. 4,636,609, which is expressly incorporated herein by reference. 
     As is well known, lasers provide a focused beam of electromagnetic radiation at a specified frequency (i.e., coherent monochromatic radiation). There are a number of types of lasers available; however, infrared lasers or non-coherent sources provide a relatively economical source of radiative energy for use in heating a welding zone. One particular example of infrared welding is known as Through-Transmission Infrared Welding (TTIR). TTIR welding employs an infrared laser capable of producing infrared radiation that is directed by fiber optics, waveguides, or light guides through a first plastic part and into a second plastic part. This first plastic part is often referred to as the transmissive piece, since it generally permits the laser beam from the laser to pass therethrough. However, the second plastic part is often referred to as absorptive piece, since this piece generally absorbs the radiative energy of the laser beam to produce heat in the welding zone. This heat in the welding zone causes the transmissive piece and the absorptive piece to be melted and thus welded together. However, the heat produced by conventional laser systems often fail to provide a consistent, reliable, and esthetically pleasing weld, which can lead to excessive waste and/or increased production costs. 
     Radiative energy produced by the infrared laser can be delivered to the targeted weld zone through a number of transmission devices—such as a single optical fiber, a fiber optic bundle, a waveguide, a light guide, or the like—or simply by directing a laser beam at the targeted weld zone. In the case of a fiber optic bundle, the bundle may be arranged to produce either a single point source laser beam, often used for spot welding, or a generally linearly distributed laser beam, often used for a linear weld. Each of these arrangements and transmission devices suffer from a number of disadvantages inherent in their designs. 
     By way of example, a single optical fiber typically produces an output beam having a generally-Gaussian laser intensity—the center of the targeted weld zone receives an increased concentration of radiative energy relative to the outer edges of the weld zone. This increased concentration of radiative energy near the center of the weld zone often causes the center of the weld zone to become overheated, resulting in disadvantageous “bubbling” and/or out-gassing in the center area of the weld zone. 
     However, this overheating and the resultant “bubbling” and/or outgassing in the center area of the weld zone is not overcome simply by using a fiber optic bundle. Although it is known that a fiber optic bundle causes the generally-Gaussian or parabolic laser intensity output from a single optic fiber to be substantially normalized to produce an overall, generally uniform, laser intensity output, the center area of the weld zone is still often overheated. In the art, this overall, generally uniform, laser intensity output from a fiber optic bundle is known as a “top hat” distribution, which is a relatively accurate representation in near-field applications. 
     However, what is not readily appreciated in the art today is that although a generally-uniform laser intensity output can be achieved using a fiber optic bundle, such uniform intensity beams do not necessarily reduce the overheating, “bubbling”, and/or out-gassing in the center area of the weld zone. Due to heat transfer principles, even with a uniform intensity beam, heat will build up faster in the center of the weld zone than along the edges of the weld zone. 
     Accordingly, there exists a need in the relevant art to provide an apparatus capable of producing an evenly distributed temperature profile throughout a target zone in order to produce a consistent weld joint. Furthermore, there exists a need in the relevant art to provide an apparatus capable of minimizing out-gassing or bubbling of a weld joint. Still further, there exists a need in the relevant art to provide an apparatus capable of redistributing radiative energy to the edge of a targeted weld zone to produce a more uniform temperature distribution. Additionally, there exists a need in the relevant art to provide an apparatus and method of using the same that is capable of overcoming the disadvantages of the prior art. 
     SUMMARY OF THE INVENTION 
     According to the principles of the present invention, a laser welding lens assembly for welding a first article to a second article at a weld zone is provided having an advantageous construction. The laser welding lens assembly includes a laser source outputting a laser beam. An optical fiber is operably coupled to the laser source to receive and transmit the laser beam. A lens is then positioned to receive the laser beam from the optical fiber. The lens includes a contoured face that is shaped to refract the laser beam to produce a generally uniform temperature profile across the weld zone. 
     Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
     FIG. 1 is an end view illustrating a laser welding lens assembly according to a first embodiment of the present invention; 
     FIG. 2 is a cross-sectional view illustrating the laser welding lens assembly along line  2 — 2  of FIG. 1; 
     FIG. 3 is a perspective view illustrating a laser welding lens assembly according to a second embodiment of the present invention; 
     FIG. 4 is an end view illustrating the laser welding lens assembly according to the second embodiment of the present invention; 
     FIG. 5 is a cross-sectional view illustrating the laser welding lens assembly along line  5 — 5  of FIG. 4; 
     FIG. 6 is a graph illustrating a temperature distribution for a uniform intensity, spot welding, laser beam; 
     FIG. 7 is a graph illustrating a laser intensity distribution normalized for uniform temperature for a spot welding laser beam; 
     FIG. 8 is a graph illustrating a preferred lens shape for a spot weld capable of achieving a uniform temperature distribution according to the principles of the present invention; 
     FIG. 9 is a graph illustrating a temperature distribution for a uniform intensity, linear welding, laser beam; 
     FIG. 10 is a graph illustrating a laser intensity distribution normalized for uniform temperature for a linear welding laser beam; 
     FIG. 11 is a graph illustrating a preferred lens shape for a linear weld capable of achieving a uniform temperature distribution according to the principles of the present invention; 
     FIG. 12 is a cross-sectional view illustrating a laser welding lens assembly according to a third embodiment of the present invention; and 
     FIG. 13 is a flowchart illustrating the method steps of determining a lens shape capable of distributing a uniform temperature laser beam according to the principles of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. 
     Referring now to the figures, a laser welding lens assembly, generally indicated at reference numeral  10 , is provided according to a first embodiment of the present invention. As best seen in FIGS. 1 and 2, laser welding lens assembly  10  includes a fiber optic bundle  12  having a plurality of optical fibers  14  generally arranged in a circular pattern capable of carrying or transmitting radiative energy in the form of a laser beam therethrough. Fiber optic bundle  12  is operably coupled to a laser source  16 , such as an infrared laser, according to known principles. Laser welding lens assembly  10  further includes a waveguide  18 , a tailored lens  20 , and a window  22 . Waveguide  18  is coupled to fiber optic bundle  12  along an interface  24 . Fiber optic bundle  12  terminates at an end  26  within waveguide  18  generally adjacent tailored lens  20 . Tailored lens  20  is securely retained within waveguide  18  and is capable of redistributing the laser beam in a uniform temperature distribution across a weld zone  28 , which will be discussed in detail below. Window  22  is coupled to an end of waveguide  18  and is retained therein to protect tailored lens  20  from environment contaminates and/or damage. 
     In operation, laser source  16  outputs a laser beam that is carried by fiber optic bundle  12 . This laser beam passes through tailored lens  20  and is redistributed to achieve a uniform temperature distribution across weld zone  28 . The laser beam then exits waveguide  18  and passes through a first plastic part  30 , also known as a transmissive piece. Transmissive piece  30  generally permits the laser beam to pass therethrough. The laser beam is then absorbed by a second plastic part  32 , also known as an absorptive piece. Absorptive piece  32  generally absorbs the radiative energy of the laser beam to produce heat in weld zone  28 . This heat causes transmissive piece  30  and absorptive piece  32  to be melted and thus welded together. 
     Still referring to FIGS. 1 and 2, as described above, tailored lens  20  is capable of redistributing the laser beam in a uniform temperature distribution across weld zone  28 . This allows for uniform welding across weld zone  28  and, thus, prevents overheating, bubbling, and/or out-gassing at or near weld zone  28 . The actual cross-sectional design of tailored lens  20  is unique in that it redistributes the laser beam to achieve increased intensity along the edges of weld zone  28  to in turn achieve a uniform temperature distribution across weld zone  28 . 
     Turning now to FIGS. 3-5, a laser welding lens assembly, generally indicated at reference numeral  10 ′, is provided according to a second embodiment of the present invention. As best seen in FIGS. 1 and 2, laser welding lens assembly  10 ′ includes a fiber optic bundle  12 ′ having a plurality of optical fibers  14  generally arranged in a side-by-side arrangement capable of carrying or transmitting radiative energy in the form of a laser beam therethrough. Fiber optic bundle  12 ′ is operably coupled to laser source  16  according to known principles. Laser welding lens assembly  10 ′ further includes a linear weld waveguide  34  and a tailored lens  20 ′. Linear weld waveguide  35  is coupled to fiber optic bundle  12 ′ along an interface  24 ′. Fiber optic bundle  12 ′ terminates at an end  26 ′ within linear weld waveguide  35  generally adjacent tailored lens  20 ′. Tailored lens  20 ′ is securely retained within linear weld waveguide  34  and is capable of redistributing the laser beam in a uniform temperature distribution across an elongated weld zone  28 , which will be discussed in detail below. 
     In operation, laser source  16  outputs a laser beam that is carried by fiber optic bundle  12 ′. This laser beam passes through tailored lens  20 ′ and is redistributed into a uniform temperature distribution. The laser beam then exits linear weld waveguide  35  and passes through a first plastic part  30 , also known as a transmissive piece. Transmissive piece  30  generally permits the laser beam to pass therethrough. The laser beam is then absorbed by a second plastic part  32 , also known as an absorptive piece. Absorptive piece  32  generally absorbs the radiative energy of the laser beam to produce heat in weld zone  28 . This heat causes transmissive piece  30  and absorptive piece  32  to be melted and thus welded together. Laser welding lens assembly  10 ′ is capable of producing an elongated laser beam adapted for linear welding applications due to the elongated shape of tailored lens  20 ′. 
     As described above, tailored lens  20 ,  20 ′ are capable of redistributing the laser beam in a uniform temperature distribution across weld zone  28 . This allows for uniform welding across weld zone  28  and, thus, prevents overheating, bubbling, and/or out-gassing at or near weld zone  28 . 
     With particular reference to FIGS. 1 and 2, tailored lens  20  is generally cylindrical in shape and includes a flat face  34  and a contoured face  36 . Similarly, with reference to FIGS. 3-5, tailored lens  20 ′ is generally elongated in shape and includes a flat face  34 ′ and a contoured face  36 ′. It should be understood that flat face  34 ,  34 ′ may also be contoured in order to achieve the desired laser beam distribution. The shape of contoured face  36 ,  36 ′ is determined through a process of mapping input light ray positions to output light ray positions, which yield the same temperature distribution. 
     This process of determining the exact contour of contoured face  36 ,  36 ′ will now be discussed in reference to a single application. With particular reference to FIG. 6, a temperature distribution graph is provided that illustrates the temperature distribution of a uniform-intensity laser beam exiting fiber optic bundle  12 , without the use of tailored lens  20 . It should be appreciated that this temperature distribution is generally-parabolically shaped and, thus, has a higher temperature A in the middle of the distribution than along the edges. This higher temperature in the middle of the distribution may cause the aforementioned overheating, bubbling, and/or out-gassing at or near weld zone  28 . However, in order to achieve a uniform temperature distribution across weld zone  28 , it is first necessary to employ a finite element analysis (FEA) program to determine the necessary intensity distribution capable of achieving a uniform temperature distribution. Accordingly, as seen in FIG. 7, a laser intensity distribution graph is produced that illustrates the laser intensity distribution (q) necessary to achieve a uniform temperature (T) at weld zone  28 . As can be seen from peaks B and valley C of FIG. 7, it is necessary to direct increased laser intensity to the outer edges of the weld zone  28 , since according to heat transfer principles these outer edges of weld zone  28  require additional laser intensity to raise their temperature as they are surrounded by unheated (i.e. cooler) areas. However, the center of weld zone  28  requires comparatively less laser intensity because it is surrounded by heated areas and, thus, will heat up more quickly. 
     In order to derive the light intensity output at the weld (q x ) for a desired uniform welding temperature (T), it is necessary to use the following formula: 
     
       
           q   x   =q *( T−T   0 )/( T   x   −T   0 ) 
       
     
     where q x  is the desired light intensity output at a given x position, q is the starting uniform light intensity used in the FEA program, T is the desired uniform welding temperature, T x  is the temperature at a given x position derived from the FEA program, and T 0  is the ambient temperature. If we then assume that the input light has parallel rays, we then use the actual intensity of the input light at a given x position to map the input light ray positions to the output light ray positions to yield a uniform temperature distribution. 
     It is then necessary to calculate the lens slope at a given x position. needed for a given index of refraction to bend the input light ray to the desired output light ray position. These slopes are then integrated to define the lens shape as seen in FIG.  8 . With particular reference to FIG. 8, we can see the desired lens shape for a generally-Gaussian distributed input laser beam is a generally concave, divergent lens. However, with closer inspection of the preferred shape of contoured face  36  we see that the preferred shape for this particular application is actually a complex shape—including both convex and concave portions. That is, we can see that the center portion of the curve in FIG. 8 is generally concave shaped between about 0.05 inches and 0.2 inches having an increasing slope outwardly from its center (generally indicated at D). However, the portion of the curve between about 0-0.05 inches and 0.2-0.25 inches is generally convex having a decreasing slope as we travel outwardly from the center concave portion (generally indicated at E). The particular shape of contoured face  36 , however, is dependent upon the particular application parameters set forth in the above equation and thus may vary. 
     Applying the above analysis and computation to laser welding lens assembly  10 ′ (linear weld application), we see from FIG. 9 that the initial temperature distribution curve for a uniform laser intensity (q) is slightly different than that set forth in FIG.  6 . However, we can still see the characteristic domed curve. Accordingly, in order to achieve a generally uniform temperature distribution, it is necessary to redistribute the laser light to the edges, as seen by peaks F in FIG.  10 . Applying the above equation and computation, a lens shape is again determined for the specific application (in this case, a linear weld) as seen in FIG.  11 . As can been seen in FIG. 10, contoured face  36 ′ is again a complex shape—including both convex and concave portions. That is, the center portion of contoured face  36 ′ is generally concave shaped between about 0.03 inches and 0.09 inches having an increasing slope outwardly from its center (generally indicated at G). The portion of the curve between about 0-0.03 inches and 0.09-0.13 inches is generally convex having a decreasing slope as we travel outwardly from the center concave portion (generally indicated at H). 
     Preferably, tailored lens  20 ,  20 ′ is made of a silicone material, however tailored lens  20 ,  20 ′ may be made of any material typically used in lens construction, including glass, acrylic, plastic, polycarbonate, and the like. An advantage to using silicone, however, is the fact that tailored lens  20 ′ and waveguide  24 ′ can be made or mechanically curved to permit the welding around corners or into tight and/or complex areas. An additional advantage of using silicon is its ability to resist particulates or other debris from sticking thereto. 
     It should be appreciated that although it is preferred that the shape of contoured face  36 ,  36 ′ is determined from an analysis and mapping of light intensity to a specific output position, it should be understood that many of the advantages of the present invention may be achieved using a concave divergent lens  50  in combination with a waveguide  51 , as seen in FIG.  12 . Concave divergent lens  50  may be a plano-concave, a concave-plano, concave-concave, or any other divergent lens system. The shape of concave divergent lens  50  and the length and inner diameter of waveguide  51  is selected such that as the laser beam exits concave divergent lens  50 , the now cone-shaped laser beam reflects off an inner portion  52  of waveguide  51 . A length  54  of waveguide downstream from concave divergent lens  50  is selected to permit only a predetermined portion of the cone-shaped laser beam to reflect off inner portion to produce a higher laser intensity distribution the edges of weld zone  28  than in the center of weld zone  28 . Consequently, as discussed in connection with the previous embodiments, concave divergent lens  50  and waveguide  51  cooperate to tailor the appropriate laser intensity distribution necessary to achieve a uniform temperature distribution across weld zone  28 . 
     The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.