Exposure Head Calibration via Polygon Mirror Beam Reflection
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Solution Overview
Problem
The increasing use of wire harnesses in transportation machines leads to weight and space issues, prompting the need for alternatives like long sheet-like flexible printed circuits, which require efficient exposure beam calibration systems for patterning without increasing device size.
Innovation Solution
An exposure head with a polygon mirror, optical elements, and a reflecting mirror that allows for one-dimensional scanning and intensity calibration of the exposure beam, integrated with a calibration system and drawing device, enabling precise beam control without enlarging the device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If wire harnesses are used for power supply and signal transmission in transportation machines, then electrical connectivity is achieved, but weight and space occupation increase
Solution Approach 1:
The patent replaces the mechanical wire harness system with a direct imaging exposure system that patterns circuits directly onto flexible substrates. The exposure head with polygon mirror and beam shaping optical system eliminates the need for traditional wire harness assemblies, achieving weight reduction while maintaining electrical connectivity through alternative circuit formation methods
2Weight of moving object
If long sheet-like flexible printed circuits are used to replace wire harnesses, then weight and space are reduced, but precise pattern formation requires complex exposure beam calibration
Solution Approach 1:
The exposure head is designed with multi-functionality, integrating both exposure and calibration capabilities into a single device. The polygon mirror and beam shaping optical system serve dual purposes: patterning circuits during normal operation and enabling calibration measurements by directing beams to detection positions, thereby reducing overall system complexity
Solution Approach 2:
The patent introduces a light-receiving element as an intermediary component that facilitates calibration without adding significant complexity. This detector acts as a mediator between the exposure beam system and the control system, enabling precise intensity calibration through feedback while maintaining a compact overall structure
3Manufacturing precision
If exposure beam intensity calibration is performed accurately, then pattern formation precision is improved, but device size increases
Solution Approach 1:
The calibration system components are nested within the existing exposure head structure. The light-receiving element is positioned to detect beams reflected from the polygon mirror without requiring separate external calibration equipment. This nested arrangement achieves accurate calibration functionality while minimizing additional space requirements
Solution Approach 2:
The patent utilizes the spatial dimension efficiently by positioning the light-receiving element at a location where it can detect calibration beams reflected from the polygon mirror. This three-dimensional arrangement of optical components allows calibration functionality to be integrated without increasing the footprint of the exposure head
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
Enables efficient calibration of exposure beam intensity for patterning on flexible printed circuits, reducing device size and ensuring reliable pattern formation on substrates, thereby addressing weight and space concerns in transportation machines.
Implementation Method 1
a polygon mirror that has multiple reflecting surfaces and is provided in a rotatable manner; an optical element that is configured to cause the beam emitted from a light source and shaped into a beam shape to enter the polygon mirror
Implementation Method 2
an imaging optical system that is configured to image the beam reflected by the polygon mirror onto an exposure surface of the substrate
Implementation Method 3
a light-receiving element that is arranged at a position where the beam reflected by the reflecting mirror can enter the light-receiving element, and that is capable of detecting an intensity of the beam
Data Source
AI summary
The exposure head is for irradiating a substrate conveyed in a predetermined direction with an exposure beam while scanning the substrate with the exposure beam in a one-dimensional manner, and the exposure head includes: a polygon mirror having multiple reflecting surfaces and provided rotatably; an optical element configured to cause the beam emitted from a light source and shaped into a beam shape to enter the polygon mirror; an imaging optical system configured to image the beam reflected by the polygon mirror onto an exposure surface of the substrate, a reflecting mirror provided insertably into or removably from the optical path of the beam shaped into the beam shape entering the optical element, the reflecting mirror being configured to reflect the beam in a direction different from the optical path while being inserted into the optical path; and a light-receiving element arranged at a position where the beam reflected by the reflecting mirror can enter the light-receiving element, and that is capable detecting an intensity of the beam.