Free-Space Laser Beam Transmission for Stable Multi-Head Patterning
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Solution Overview
Problem
The use of ultrashort pulse lasers in laser processing machines for perovskite-type solar cells leads to fiber breakage and laser beam instability due to long optical path lengths and complex configurations, making it difficult to maintain consistent processing quality across multiple processing heads.
Innovation Solution
A laser processing machine with a space transmission device that includes an optical member to change the beam diameter and an attenuator to adjust transmittance, ensuring stable laser beam quality by using picosecond or femtosecond lasers, and employing a beam transmitter with a drive mechanism to control beam diameter and power uniformly across multiple irradiators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If ultrashort pulse lasers are used for high-precision patterning, then processing quality and line width are improved, but fiber transmission becomes unstable and laser state changes occur
Solution Approach 1:
The patent replaces fiber optic transmission with free-space optical transmission using mirrors and lenses. This substitution eliminates the fiber breakage and laser state changes that occur with ultrashort pulse lasers in fiber transmission, while maintaining the ability to deliver high-precision patterning capability to multiple processing heads.
Solution Approach 2:
The patent introduces free space as an intermediary medium between the laser source and processing heads. By using mirrors and lenses in free space rather than confining the laser beam within fiber optics, the system maintains ultrashort pulse laser stability while achieving reliable transmission to multiple irradiators.
2Productivity
If multiple processing heads are arranged to improve productivity, then output increases, but optical path length increases causing laser state changes
Solution Approach 1:
The patent divides the optical system into multiple independent free-space optical paths, each serving a processing head. By segmenting the laser beam transmission into separate optical paths with individual mirrors and lenses, the system can serve multiple processing heads while maintaining consistent laser state in each path, preventing the degradation that would occur with a single long optical path.
Solution Approach 2:
The patent transitions from a linear optical path arrangement to a multi-dimensional free-space optical configuration. By using mirrors to redirect beams in multiple directions and lenses to focus at different positions in three-dimensional space, the system can deliver laser beams to multiple processing heads arranged in different spatial locations without extending a single long optical path.
3Manufacturing precision
If beam diameter and power are adjusted uniformly across multiple irradiators, then processing quality consistency is improved, but device complexity increases
Solution Approach 1:
The patent implements universal optical components (mirrors and lenses) that can be configured to perform multiple functions: beam direction, focusing, and power distribution. By using the same types of components across all optical paths with different configurations, the system achieves uniform beam parameters across multiple irradiators while avoiding the need for entirely different component sets, thereby limiting the increase in complexity.
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 solution maintains consistent processing quality and reduces laser state changes, ensuring uniform laser power and beam diameter across multiple axes, thereby enhancing the precision and efficiency of patterning processing in thin film solar cells.
Implementation Method 1
an optical member configured to change a beam diameter of the laser beam
Implementation Method 2
an optical member configured to change a beam diameter of the laser beam
Implementation Method 3
an attenuator configured to change a transmittance of the laser beam
Data Source
AI summary
A space transmission device used in a laser processing machine. The laser processing machine including a laser oscillator configured to oscillate a laser beam having a pulse width in a picosecond order or a femtosecond order, and a plurality of irradiators. The space transmission device includes an optical member configured to change a beam diameter of the laser beam, on an optical path of the laser beam that is emitted from the laser oscillator and that is incident on any one of the plurality of irradiators.