Annular Beam Laser Machining Uniform Intensity
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Solution Overview
Problem
Traditional laser machining apparatuses face issues with non-uniform light intensity distribution in focused beams, leading to uneven cutting performance, energy wastage, and difficulties in half-cut manufacturing processes when processing transparent substrates like reinforced glass.
Innovation Solution
A laser uniformly machining apparatus and method that includes a laser unit, shaping, collimating, scaling, and focusing elements to produce a focused beam with a uniformly distributed light intensity, achieved by shaping the laser beam into an annular beam, modifying its direction, adjusting it with a scaling ratio, and focusing it to ensure uniform energy distribution along the optical axis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rotating prism is used as a focusing element to produce a focused beam, then the laser can process transparent substrates, but the light intensity distribution becomes non-uniform (Gaussian-like) with uniformity less than 50%, leading to uneven machining features
Solution Approach 1:
The patent changes the beam shape parameter from a conventional Gaussian profile to an annular (ring-shaped) profile. This parameter change in beam geometry, achieved through specific optical element design, transforms the light intensity distribution from non-uniform Gaussian to uniform annular distribution, directly resolving the contradiction between reliability and manufacturing precision
Solution Approach 2:
The patent introduces a new dimensional characteristic by creating an annular beam with a specific ring geometry rather than a conventional circular or point focus. This dimensional transformation from a filled circular beam to a ring-shaped beam with controlled thickness enables uniform light intensity distribution along the optical axis, solving the uniformity problem while maintaining processing capability
2Productivity
If the light intensity of the focused beam attenuates slowly in the direction of the optical axis, then the machining range is extended, but the boundaries between machining and non-machining ranges become unclear, causing damage to lower half during half-cut manufacturing
Solution Approach 1:
The patent changes the beam geometry parameter to an annular shape with controlled thickness, which fundamentally alters the light intensity attenuation characteristics. This parameter change creates a uniform intensity distribution that maintains extended machining range while providing clear, well-defined boundaries between machining and non-machining zones, resolving the contradiction between productivity and manufacturing precision
Solution Approach 2:
The patent creates a scaled annular beam by scaling the collimated annular beam, producing a focused beam that replicates the uniform intensity distribution pattern at different scales. This scaling approach maintains the beneficial uniformity and boundary definition characteristics while adapting to different machining range requirements, solving both the extended range and clear boundary needs
3Power
If the light intensity of the focused beam is distributed to 1.5 to 2 times greater than the thickness of the workpiece to ensure sufficient energy, then the machining range is adequate, but energy is wasted on non-machining ranges
Solution Approach 1:
The patent changes the beam intensity distribution parameter from Gaussian (concentrated at center) to uniform annular distribution. This parameter change allows the light energy to be evenly distributed across the required machining depth without excessive concentration at any single point, enabling adequate energy delivery to the workpiece while minimizing energy waste in non-machining regions, thus resolving the contradiction between power and energy loss
Solution Approach 2:
The patent applies local quality by creating an annular beam where the light intensity is uniformly distributed only in the specific region required for machining (the annular region), rather than distributing energy throughout an entire circular area. This localized uniform distribution ensures energy is concentrated where needed while avoiding waste in non-machining areas, resolving the power versus energy loss contradiction
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 results in improved machining quality with uniform features, reduced energy wastage, and enhanced processing speed, making it suitable for half-cut processes while lowering the building cost of the laser machining apparatus.
Implementation Method 1
a laser unit for providing a laser beam for machining
Implementation Method 2
a shaping element for shaping the laser beam into an annular beam
Implementation Method 3
a collimating element for modifying the direction of the annular beam modified by the shaping element in accordance with the direction of an optical axis to turn the annular beam into a collimated annular beam
Implementation Method 4
a focusing element for focusing the scaled annular beam produced, wherein the scaled annular beam is produced by the scaling element to form a focused beam having a uniformly distribution of light intensity in the direction of the optical axis
Data Source
AI summary
A laser uniformly machining apparatus and method thereof are provided. The apparatus includes a laser unit, a shaping element, a collimating element, a scaling element and a focusing element. The laser unit provides a laser beam for machining. The shaping element shapes the laser beam into an annular beam. The collimating element modifies the direction of the annular beam in accordance with the direction of an optical axis to turn the annular beam into a collimated annular beam. The scaling element adjusts the collimated annular beam in accordance with a scaling ratio to produce a scaled annular beam. The focusing element focuses the scaled annular beam. The scaled annular beam is produced by the scaling element to form a focused beam having a uniformly distribution of light intensity in the direction of the optical axis.