Aspheric Optical Assembly for High-Angle Glass Laser Cutting
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Solution Overview
Problem
Current methods for cutting and separating glass substrates are inefficient, resulting in square edges prone to breakage, dust generation, and require additional cleaning steps, necessitating a faster, cleaner, and more reliable process.
Innovation Solution
A method involving a laser beam processed through an aspheric optical element with a radial offset, producing a quasi-non-diffracting beam that impinges the glass substrate at a high angle, creating angled defects for efficient separation with minimal divergence and aberration, using a multi-optic axicon assembly or axicon lenses to maintain beam quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cutting methods are used to separate glass substrates, then the process is simple and straightforward, but the edges produced are square and prone to breakage, requiring additional mechanical grinding and polishing steps
Solution Approach 1:
The patent replaces mechanical cutting methods with laser-based processing. A laser beam is directed through an optical element at a high angle (greater than 45 degrees relative to the surface normal) to create angled defects within the glass substrate. This substitution eliminates the need for mechanical grinding and polishing while producing edges that are less prone to breakage, thereby improving both reliability and productivity.
Solution Approach 2:
The patent changes the processing parameters by using high-angle laser incidence instead of conventional low-angle or perpendicular cutting. The laser beam is directed at angles greater than 45 degrees relative to the surface normal, which creates angled defects rather than square edges. This parameter change fundamentally alters the edge geometry and structural integrity of the cut glass substrates.
2Reliability
If mechanical grinding and polishing are used to finish edges, then breakage risk is reduced, but glass dust and particles are generated requiring additional cleaning steps
Solution Approach 1:
The patent replaces mechanical grinding and polishing with laser-based high-angle processing. By directing the laser beam at high angles (greater than 45 degrees) to create angled defects, the process achieves edge strengthening without the mechanical contact that generates glass dust and particles. This eliminates the harmful byproducts while maintaining improved edge strength.
Solution Approach 2:
The patent converts the potential harm of laser processing (which could generate debris) into a benefit by using high-angle incidence. This specific angle creates angled defects that strengthen edges while the laser's precision prevents excessive material removal and dust generation. The process transforms what could be a harmful mechanical operation into a clean, controlled energy-based process.
3Reliability
If high-angle laser processing is used to create angled defects, then edge strength is improved and dust generation is reduced, but beam divergence and aberration increase
Solution Approach 1:
The patent introduces an optical element as an intermediary between the laser beam source and the glass substrate. This optical element is specifically designed to receive the laser beam and redirect it at high angles (greater than 45 degrees) relative to the substrate surface normal. The optical element acts as a mediator that enables high-angle processing while managing beam quality challenges through its optical design.
Solution Approach 2:
The patent changes the dimensional approach by processing in a high-angle geometry rather than conventional low-angle or perpendicular cutting. The laser beam is directed at angles greater than 45 degrees relative to the surface normal, creating a three-dimensional angled defect structure within the glass substrate. This dimensional change in processing geometry fundamentally improves edge strength while the optical element manages the associated beam quality considerations.
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 enables precise, particle-free cutting of glass substrates with angled edges, reducing breakage risk and eliminating the need for mechanical grinding, while maintaining high throughput and accuracy.
Implementation Method 1
The beam pathway and the transparent workpiece are tilted relative to one another such that the beam pathway has a beam pathway angle of less than 90° relative to the impingement surface at the impingement surface
Implementation Method 2
a portion of the laser beam directed into the transparent workpiece is a laser beam focal line and generates an induced absorption to produce a defect within the transparent workpiece
Implementation Method 3
The laser beam downstream the aspheric optical element has non-uniform radial intensity... such that the defect has a defect angle within the transparent workpiece of less than 80° relative to the impingement surface
Data Source
AI summary
A method for processing a transparent workpiece includes directing a laser beam oriented along a beam pathway through an aspheric optical element and the transparent workpiece. The laser beam impinges the aspheric optical element radially offset from a centerline axis of the aspheric optical element by an offset distance of 30% the 1/e2 diameter of the laser beam or greater. The beam pathway and the transparent workpiece are tilted relative to one another such that the beam pathway has a beam pathway angle of less than 90° relative to an impingement surface at the impingement surface and a portion of the laser beam directed into the transparent workpiece is a laser beam focal line having an internal focal line angle of less than 80° relative to the impingement surface, such that a defect with a defect angle of less than 80° is formed by induced absorption within the transparent workpiece.