Laser Beam Splitting for Multi-Hole Drilling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing laser drilling systems using multiple beams lack flexibility in operating parameters, such as energy distribution and pulse repetition rates, which hinders efficient drilling of holes in substrates with varying materials and hole depths.
Innovation Solution
A method and system that dynamically adjust the energy and power of laser beams by dividing a single output beam into multiple sub-beams with varying pulse energies and repetition rates over time, allowing for simultaneous and sequential drilling of holes with different energy fractions based on the number of holes being drilled, using an acousto-optic deflector and programmable mirrors to control beam direction and energy distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple laser beams are used to drill multiple holes simultaneously, then productivity is improved, but device complexity increases due to the need for multiple independent beam sources and control systems
Solution Approach 1:
The patent divides a single laser beam into multiple sub-beams using beam splitting optics. This segmentation allows one laser source to create multiple drilling beams, achieving multi-hole simultaneous drilling without requiring multiple independent laser systems, thus improving productivity while avoiding the complexity of multiple beam sources
Solution Approach 2:
The single laser beam serves multiple functions by being split into multiple sub-beams that can drill multiple holes simultaneously. The beam splitting system enables one laser source to perform the work of multiple lasers, reducing system complexity while maintaining high productivity
2Adaptability or versatility
If fixed energy distribution is used among multiple beams, then device complexity is reduced, but adaptability deteriorates when drilling holes with varying depths and materials
Solution Approach 1:
The patent implements dynamic energy distribution by allowing variable attenuation of each sub-beam through adjustable optical elements. This enables the system to adapt energy levels to different drilling requirements (depth, material) in real-time, providing flexibility without requiring multiple independent laser sources with separate control systems
Solution Approach 2:
The system changes the energy parameters of sub-beams by varying the attenuation levels of individual beams. This allows each sub-beam to be optimized for specific drilling conditions while maintaining a single laser source, achieving adaptability without proportionally increasing system complexity
3Productivity
If equal pulse energy is distributed to all sub-beams, then manufacturing precision is maintained, but productivity decreases when some holes require more energy than others
Solution Approach 1:
The patent applies different energy levels to different sub-beams based on local drilling requirements. Each sub-beam can be independently attenuated to provide the appropriate energy for its specific target, allowing holes of varying depths and materials to be drilled with optimal energy while maintaining overall process efficiency
Solution Approach 2:
The system varies the energy parameters of individual sub-beams to match local drilling conditions. By adjusting attenuation levels, each beam delivers the precise energy needed for its specific hole, improving both productivity and hole quality consistency compared to uniform energy distribution
4Loss of time
If sequential drilling is used instead of simultaneous multi-hole drilling, then device complexity is reduced, but loss of time increases
Solution Approach 1:
The patent segments a single laser beam into multiple sub-beams that can drill multiple holes simultaneously. This segmentation enables parallel processing of multiple holes, dramatically reducing total drilling time compared to sequential drilling, while the beam splitting optics add manageable complexity to the system
Solution Approach 2:
The system maintains continuous useful action by having multiple sub-beams drill multiple holes simultaneously rather than sequentially. This parallel operation eliminates idle time between holes and maintains continuous material removal across multiple locations, significantly reducing total processing time
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 enhances the flexibility and efficiency of laser drilling by optimizing energy usage and reducing drilling time across different substrate layers and hole depths, allowing for precise control of drilling processes.
Implementation Method 1
dividing the single output beam into plural beams... using an acousto-optic deflector
Implementation Method 2
laser drilling of holes in a substrate... laser beams have been used in fabrication systems... for such purposes as drilling, fusion, or ablation of the object
Data Source
AI summary
A method for laser drilling of holes in a substrate (44) with varying simultaneity including operating a laser (22) to produce a single output beam (24) whose pulses have a total energy, dividing the single output beam into plural beams (41) to an extent which varies over time and applying the plural beams to plural hole drilling locations (209, 210, 212, 214, 216, 218, 220, 222) on the substrate including simultaneously drilling first parts of multiple holes using corresponding ones of the plural beams having a pulse energy which is a first fraction of the total energy and thereafter drilling at least one second part of at least one of the multiple holes using at least one of the plural beams each having a pulse energy which is at least a second fraction of the total energy, the second fraction being different from the first fraction.