Diffracted Laser Patterning for Uniform Large-Area Surface Processing
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Solution Overview
Problem
Conventional methods for forming patterns on metal surfaces using abrasives or laser processing are limited by non-uniformity and inefficiency, particularly when dealing with complex patterns or large areas, and lack a systematic approach to abrasive exchange and pattern formation.
Innovation Solution
A processing device and method utilizing diffraction of a laser beam to uniformly process a surface, featuring a laser transmission unit with a diffraction optical system, an actuator for pattern manipulation, and a controller for precise control of the laser beam emission, allowing for vertical, horizontal, and directional pattern formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional laser beam source is used to process a large area or complex pattern, then processing quality and precision are maintained, but processing time increases significantly, decreasing working efficiency
Solution Approach 1:
The patent divides a single laser beam into multiple beams using a beam splitter and diffraction grating. The single laser source is segmented into multiple parallel beams that can simultaneously process different areas of the workpiece, thereby maintaining precision while significantly improving processing speed and productivity for large areas and complex patterns.
2Adaptability or versatility
If abrasives are used to form patterns on metal surfaces, then various pattern sizes can be achieved, but pattern uniformity deteriorates due to crystal irregularities and pore formation
Solution Approach 1:
The patent replaces the mechanical abrasion process with a laser-based optical system. Instead of using abrasive crystals that create uniformity issues, the system uses laser beams with controllable parameters to form patterns, eliminating the harmful effects of abrasive crystal irregularities and pore formation while maintaining the ability to create various pattern sizes.
3Device complexity
If a single laser beam is used for processing, then equipment complexity is minimized, but the ability to process complex patterns and large areas efficiently is limited
Solution Approach 1:
The patent uses a beam splitter to divide a single laser beam into multiple beams, creating a multi-beam system from one laser source. This approach maintains equipment simplicity (only one laser source needed) while achieving the productivity benefits of multiple beams processing simultaneously, thus resolving the contradiction between device complexity and processing efficiency.
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 and efficient pattern formation on metal surfaces with uniformly diffracted laser beams, improving work efficiency and reducing costs by minimizing the need for multiple laser sources and maintenance, while allowing for various pattern shapes and sizes.
Implementation Method 1
a laser transmission unit that is formed at a first portion of the device main body, and configured to diffract the laser beam emitted from the laser source so that a diffracted laser beam is emitted toward the object to be processed
Data Source
AI summary
A processing device to form a pattern on a surface of an object to be processed using diffraction of a laser beam emitted from a laser source, the device including: a main body providing a space to process the object using the laser beam emitted from the laser source; a laser transmission unit formed at a first portion of the main body, and configured to diffract the laser beam so that a diffracted laser beam is emitted toward the object; an actuator formed at a second portion of the main body, and connected to the laser transmission unit so as to change an emission pattern of the diffracted laser beam while rotating the laser transmission unit vertically/horizontally or in a set radius; and a controller provided at a third portion of the main body, and connected to the actuator to control an operation of the actuator.