Glass-Ceramic Substrate Patterning via Laser Pulse Modulation
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Solution Overview
Problem
Current processing and manufacturing technologies for glass-ceramics require high-temperature annealing, which can cause thermal stresses and are not compatible with materials like electronics or plastics, limiting the single-step fabrication of multi-functional systems.
Innovation Solution
A system that enables in-situ patterning of material substrates using laser scripted pulse modulation to transform amorphous phases into discrete etchable phases, allowing for site-selective phase conversion and control of electrical, optical, mechanical, and chemical properties, enabling the creation of complex integrated systems within a single step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-temperature annealing is used for optical patterning in glass-ceramics, then the latent image can be transformed into a fixed permanent image, but thermal stresses and temperature gradients are generated that cause incompatibility with electronics, optics, plastics, organic substrates and thin films
Solution Approach 1:
The patent transforms the processing parameters from high-temperature thermal field to low-temperature optical field. By using two-photon polymerization and direct laser writing with UV or infrared lasers, the method achieves permanent image fixation without high-temperature annealing, thereby eliminating thermal stresses while maintaining the reliability of image transformation.
Solution Approach 2:
The patent replaces the thermal mechanism (high-temperature annealing) with an optical mechanism (laser irradiation). The optical system uses photopolymerization or photo-induced phase transformation to achieve the same functional result as thermal annealing, but without the harmful thermal effects.
2Reliability
If high-temperature annealing is used in conjunction with optical patterning, then permanent images can be created, but the single-step fabrication of multi-functional systems is precluded requiring separate fabrication and post-process assembly
Solution Approach 1:
The patent merges multiple fabrication steps into a single optical processing step. By using direct laser writing and two-photon polymerization, the system can simultaneously create permanent images, modify material properties, and fabricate multi-functional integrated systems in one step, eliminating the need for separate fabrication and assembly processes.
Solution Approach 2:
The optical processing system achieves multi-functionality by being able to create permanent images, modify electrical properties, optical properties, and mechanical properties all through the same laser-based mechanism. This universal approach allows single-step fabrication of complex multi-functional systems without requiring different processing equipment for each function.
3Ease of manufacture
If conventional separate fabrication of discrete elements is used, then each element can be manufactured independently, but the alignment and assembly processes increase manufacturing complexity and time
Solution Approach 1:
The patent combines the manufacturing of multiple discrete elements and their alignment into a single laser processing operation. The direct laser writing system can fabricate multiple functional elements and their interconnections simultaneously within the glass-ceramic substrate, eliminating the time-consuming separate alignment and assembly processes while maintaining independent manufacturability through digital design control.
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 the rapid design of complex, highly integrated systems with controlled electrical and optical characteristics, mechanical compliance, and chemical solubility, facilitating the creation of photonic, bionic, and electronic systems within glass-ceramic substrates without the need for high-temperature annealing.
Implementation Method 1
A laser is used to modify a glass-ceramic (GC) substrate by laser scripted pulse modulation to transform amorphous phases into discrete etchable phases
Data Source
AI summary
A system includes a computing device that generates at least one process script for the modification to a glass ceramic substrate and at least one pattern script that corresponds to the process script. The computing device also merges the process script with the pattern script and generates a plurality of command signals that are based on the merged process and pattern scripts. An energy source generates a plurality of light beams based on the generated command signal(s). A waveform apparatus generates at least one waveform signal to customize the generated light beams based on the generated command signal(s). At least one modulating component modulates the generated light beams based on generated command signal(s). An optical assembly is configured to apply the modulated plurality of light beams to the glass ceramic substrate. At least one motion stage encoder is configured to provide at least one three dimensional (3D) coordinate position of the optical assembly with respect to the motion control drive in order to coordinate application of the modulated light beams with a predefined spatial location.