Defocused Laser Etching Light Diffuser Stencil
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Solution Overview
Problem
Current methods for laser etching of diffuser panels in edge-lit lighting systems are time-consuming and increase production costs due to the need for multiple passes of a focused laser to create disruptions, which are then scattered to evenly emit light.
Innovation Solution
A method and system utilizing a defocused laser beam scanned over openings in a stencil, allowing a single pass to create a row of disruptions with a width matching the desired pattern, reducing the need for multiple passes and power cycling, and enabling efficient etching and cutting of panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a focused laser is used to etch disruptions on the panel surface, then manufacturing precision is improved, but productivity deteriorates due to multiple passes being required
Solution Approach 1:
The patent changes the focusing parameter of the laser beam from focused to defocused. This parameter change allows a single pass to create the desired disruption pattern, resolving the contradiction by improving productivity while maintaining acceptable manufacturing precision through the defocused beam's broader coverage area
2Manufacturing precision
If a focused laser is used to create disruptions, then manufacturing precision is improved, but loss of time increases due to multiple passes and power cycling
Solution Approach 1:
The patent applies parameter change by switching from a focused laser mode to a defocused laser mode. This eliminates the need for multiple passes and power cycling operations, significantly reducing production time while still achieving the required disruption pattern precision in a single continuous pass
3Productivity
If a defocused laser beam is used, then productivity is improved by enabling single-pass etching, but manufacturing precision may deteriorate due to beam width being larger than desired disruption size
Solution Approach 1:
The patent introduces a stencil as an intermediary element between the defocused laser beam and the panel surface. The stencil with its precisely positioned openings controls the beam's interaction with the panel, ensuring that disruptions are created only at the desired locations and sizes, thus maintaining manufacturing precision while benefiting from the high productivity of defocused single-pass etching
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 significantly reduces production time and costs by enabling a single pass to create a row of disruptions, enhancing the efficiency of light emission from the panel surface while allowing for precise control over disruption size and pattern.
Implementation Method 1
A defocused laser beam generated by the laser head is scanned over the openings in the stencil. The width of the defocused laser beam at a location at which the laser beam strikes the panel is at least as large as a size of the desired disruption, and the laser head is powered at a level and moved at a rate that creates a disruption in the surface of the panel at each opening.
Data Source
AI summary
Approaches for making a light-transmitting panel are disclosed. A panel is positioned on a support structure, and a stencil is positioned between a surface of the panel and a laser head. The stencil includes a plurality of openings. A defocused laser beam generated by the laser head is scanned over the openings in the stencil. The width of the defocused laser beam at a location at which the laser beam strikes the panel is at least as large as a size of the desired disruption, and the laser head is powered at a level and moved at a rate that creates a disruption in the surface of the panel at each opening.