Composite Photoconductor Light Valve for Large Clear Apertures
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Solution Overview
Problem
Conventional high energy/power light valves are limited in size due to the size constraints of their photoconductors, which are typically Bismuth Silicate crystal plates, leading to a maximum clear aperture of 30 mm×30 mm, restricting the production rate of metal additive manufacturing.
Innovation Solution
The use of a composite structure comprising a photoconductor plate bonded to a stiff and flat supporting substrate, such as C-cut sapphire or crystalline quartz, allows for larger clear apertures by enabling the photoconductor to be deformed and polished without distortion, and enables refurbishment of damaged parts, thus allowing for larger area light valves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional large crystal boules are grown to acquire larger photoconductor plates, then the clear aperture of light valves can be increased, but the yield decreases due to impurities and defects
Solution Approach 1:
The patent divides the large area light valve into multiple smaller photoconductor plates (e.g., four 30mm×30mm plates) that are separately grown and then bonded together to form a composite assembly. This segmentation allows each individual plate to be grown with high yield and quality, while the composite achieves the desired large clear aperture without the defects associated with growing single large crystal boules.
2Productivity
If the clear aperture of light valves is increased to improve production rate, then more area can be processed, but the energy fluence must be kept below damage threshold which limits the effective area
Solution Approach 1:
The patent creates a composite photoconductor assembly by bonding multiple individual photoconductor plates together with bonding material between them. This composite structure allows the light valve to achieve a large clear aperture while maintaining the high laser damage threshold of the individual crystal plates, enabling increased production rate without exceeding energy fluence damage thresholds.
3Area of stationary object
If single large photoconductor plates are used, then the light valve can have large clear aperture, but optical aberrations increase and resolution uniformity decreases
Solution Approach 1:
By segmenting the large light valve into multiple smaller photoconductor plates, each plate maintains optimal optical properties and low aberrations. The segmented plates are arranged in a composite assembly where each contributes to the overall large clear aperture while maintaining individual optical quality, thereby preserving resolution uniformity across the entire aperture.
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 the production of arbitrarily large area light valves with improved resolution and contrast control, reducing manufacturing costs and increasing the production rate of metal additive manufacturing by utilizing high fluence lasers.
Implementation Method 1
a photoconductor composite assembly composed of a photoconductor plate bonded to a stiff and flat supporting substrate
Data Source
AI summary
An additive manufacturing system includes at least two photoconductor plates attached to a substrate. Each photoconductor plate can include separate the Linear Electro layers and transparent conductive oxide layers.