Encoder Scale Surface Structure to Prevent Laser Penetration
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Solution Overview
Problem
Existing scale manufacturing methods face challenges in preventing damage to formations on the lower surface of glass substrates during conductor pattern formation, leading to defects and noise issues in encoder devices due to laser penetration and non-uniformity.
Innovation Solution
A scale with a frosted glass-like upper surface and a smooth lower surface, where conductor patterns are formed on the upper surface using laser processing, preventing laser penetration and reducing surface damage, and incorporating a conductor film on the lower surface as an electromagnetic shield to suppress noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conductor patterns are formed on the upper surface of the glass substrate using laser processing, then processing time is reduced and reproducibility is improved, but laser penetration may damage formations on the lower surface of the glass substrate
Solution Approach 1:
The glass substrate is divided into two distinct surfaces with different properties: the upper surface is roughened to scatter and absorb laser energy, while the lower surface is kept smooth to protect formations. This segmentation allows the upper surface to serve as a laser protection layer without interfering with the functionality of the lower surface formations.
Solution Approach 2:
The roughened upper surface of the glass substrate acts as an intermediary layer between the laser processing source and the formations on the lower surface. This intermediary surface scatters and absorbs laser energy, preventing direct laser penetration to the sensitive formations while still allowing the laser processing to effectively create conductor patterns on the upper surface.
2Reliability
If the upper surface of the glass substrate is roughened into a frosted glass state, then laser penetration is prevented and damage to lower surface formations is reduced, but manufacturing complexity increases
Solution Approach 1:
The mechanical process of creating a roughened surface is replaced by chemical etching using hydrofluoric acid or ammonium fluoride solutions. This substitution provides more precise control over the roughening degree and achieves consistent frosted glass surfaces with better reproducibility, reducing manufacturing complexity despite the chemical process involvement.
3Reliability
If conductor patterns are formed by traditional methods, then damage to lower surface formations is minimized, but processing time increases and reproducibility decreases
Solution Approach 1:
The upper surface of the glass substrate is roughened into a frosted glass state before conductor pattern formation. This preliminary action creates a surface that scatters and absorbs laser energy, preventing laser penetration to the lower surface formations during subsequent conductor pattern creation, thereby protecting them in advance.
Solution Approach 2:
The surface roughness parameter of the upper surface is changed by roughening it into a frosted glass state. This parameter change fundamentally alters the laser interaction characteristics, enabling effective laser processing for conductor pattern formation while simultaneously preventing harmful laser penetration to the lower surface.
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 reduces processing time and improves reproducibility of conductor patterns, minimizes warpage, and prevents damage to formations on the lower surface, enhancing the bonding strength and reducing disturbances in current flow, thus improving the reliability of encoder devices.
Implementation Method 1
a glass substrate having a frosted glass-like upper surface
Implementation Method 2
forming a plurality of conductor patterns arranged at predetermined intervals on the upper surface of the glass substrate by laser processing
Implementation Method 3
incorporating a conductor film on the lower surface as an electromagnetic shield to suppress noise
Data Source
AI summary
A scale includes a glass substrate having a frosted glass-like upper surface, a plurality of conductor patterns arranged at predetermined intervals on the upper surface of the glass substrate, and a formation provided on a lower surface of the glass substrate.