Beam-Shaped Laser Machining for Transparent Material Separation
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Solution Overview
Problem
Existing laser machining technologies face challenges in effectively processing materials that are transparent to laser beams, as they struggle to achieve precise modifications and efficient material separation due to the inherent transparency of these materials, which limits the achievable geometries and accuracy of machining.
Innovation Solution
The apparatus employs a beam splitting element to split the input laser beam into component beams, which are then focused into different partial regions of a focal zone using a focusing optical unit, allowing for the introduction of the focal zone at various angles relative to the workpiece. This setup enables the formation of focal zones with diverse geometries and refractive index changes within the material, facilitating flexible and precise machining geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional laser machining methods are used on transparent materials, then the laser beam passes through the material without significant interaction, but this results in inability to achieve precise modifications and efficient material separation
Solution Approach 1:
The laser beam is segmented into multiple component beams using a beam splitting element. Each component beam is then focused into different partial regions of the focal zone, creating multiple interaction points within the transparent material. This segmentation allows the laser energy to be distributed strategically to achieve precise modifications and effective material separation despite the material's transparency.
Solution Approach 2:
Different partial regions of the focal zone are targeted with specific component beams to create localized modifications with varying geometries and refractive index changes. This local quality approach ensures that each region receives tailored laser treatment optimized for its specific machining requirements, enhancing both precision and effectiveness.
2Adaptability or versatility
If a single focal zone is used for laser machining, then the machining geometry is limited, but this restricts the achievable machining geometries and angles
Solution Approach 1:
The beam shaping system is segmented into a beam splitting element and a focusing optical unit. The beam splitting element divides the input beam into multiple component beams, which are then focused by the focusing optical unit into different partial regions. This segmented approach enables the creation of complex multi-region focal zones with diverse geometries and angles while maintaining a relatively simple overall device structure.
Solution Approach 2:
The beam shaping device performs multiple functions: it splits the input beam, focuses component beams into different regions, and creates focal zones with various geometries. This multi-functionality allows a single device to achieve diverse machining geometries and angles without requiring multiple separate optical systems, thereby reducing overall device complexity.
3Manufacturing precision
If the laser beam is focused into a single point, then the energy concentration is high, but this limits the ability to create diverse focal zone geometries and refractive index changes
Solution Approach 1:
The laser energy is segmented into multiple component beams that are focused into different partial regions of the focal zone. This segmentation allows for controlled energy distribution across multiple regions, enabling precise control over focal zone geometry and refractive index changes in each region while maintaining efficient energy utilization.
Solution Approach 2:
Each partial region of the focal zone receives focused energy with specific geometric characteristics and refractive index modification levels. This local quality approach ensures that energy is distributed according to the specific machining requirements of each region, achieving precise control over focal zone geometry and material modification while optimizing energy usage.
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 allows for flexible and precise laser machining of transparent materials by creating focal zones with specific geometries and refractive index changes, enabling efficient material modifications and separation, including the formation of smooth edges and controlled crack formation, thereby overcoming the limitations of traditional methods.
Implementation Method 1
The first input beam is split by the beam splitting element by phase imposition on the first input beam
Implementation Method 2
a focusing optical unit assigned to the first beam shaping device and configured to image the plurality of component beams output coupled from the first beam shaping device into at least one focal zone
Implementation Method 3
Material modifications associated with a change of a refractive index of the material are produced in the material by exposing the material to the at least one focal zone
Data Source
AI summary
An apparatus for laser machining a workpiece includes a first beam shaping device comprising a beam splitting element for splitting a first input beam into a plurality of component beams, and a focusing optical unit configured to image the component beams into at least one focal zone. The first input beam is split by the beam splitting element by phase imposition on the first input beam. The component beams are focused into different partial regions of the at least one focal zone for forming the at least one focal zone. The at least one focal zone is introduced into the material at a work angle with respect to an outer side of the workpiece for the laser machining of the workpiece. Material modifications associated with a change of a refractive index of the material are produced in the material by exposing the material to the at least one focal zone.