Composite Material Scribing to Minimize Brittle Layer Cracks
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Solution Overview
Problem
Existing methods for dividing composite materials with brittle and resin layers often result in cracks on the end surface of the brittle material layer and insufficient bending strength after division.
Innovation Solution
A method involving irradiation with an ultrashort pulse laser beam, where the focal point is set in the resin layer near the interface with the brittle material layer, forming a scribe groove that prevents penetration through the brittle material layer, thereby reducing cracks and enhancing bending strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the laser beam is focused deeply into the brittle material layer to form a through-hole processed mark, then the division can be initiated, but cracks occur on the end surface of the brittle material layer after division
Solution Approach 1:
The method performs preliminary scribe groove formation at a shallow depth (0.5-2 μm) before final division. This preliminary action creates a surface defect that initiates division without requiring deep penetration, thereby avoiding the crack-inducing deep focusing while still enabling effective division along the scribed line
Solution Approach 2:
The invention applies different processing depths at different stages: shallow scribe groove formation (0.5-2 μm) for crack prevention and sufficient division initiation, versus the conventional deep through-hole formation (>50 μm). This local quality differentiation resolves the contradiction by using minimal necessary depth
2Object-affected harmful factors
If the scribe groove depth is reduced to prevent cracks, then end surface quality improves, but bending strength may become insufficient
Solution Approach 1:
The invention optimizes the scribe groove depth parameter to a specific range (0.5-2 μm) that balances two competing requirements: shallow enough to prevent cracks on the end surface, yet deep enough to provide sufficient stress concentration for division initiation and maintain bending strength. This precise parameter control resolves the contradiction
3Object-affected harmful factors
If the laser focal point is set in the resin layer near the interface, then crack formation is minimized, but the processing precision required increases
Solution Approach 1:
The resin layer acts as an intermediary medium that allows the laser focal point to be positioned near the interface without directly focusing in the brittle material. This intermediary approach enables precise energy deposition at the interface region while avoiding direct focal point placement in the brittle material, thus reducing crack risk while maintaining processing precision
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 method effectively minimizes cracks on the brittle material layer's end surface and achieves sufficient bending strength for the composite material after division.
Implementation Method 1
irradiation with an ultrashort pulse laser beam, where the focal point is set in the resin layer near the interface with the brittle material layer, forming a scribe groove
Data Source
AI summary
A method for dividing a composite material 10 in which a brittle material layer 1 and a resin layer 2 are laminated, the method including: a brittle material removing step in which irradiation is performed from a brittle material layer side with a laser beam L1, which is oscillated from an ultrashort pulse laser light source 20, along a scheduled dividing line DL of the composite material to form a scribe groove 11; and a resin removing step in which the resin layer is irradiated with a laser beam L2, which is oscillated from a laser light source 30, along the scheduled dividing line to remove a resin forming the resin layer.