Laser-Induced Channels in Multi-Layer Substrates
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Solution Overview
Problem
Existing laser-based methods for forming channels in substrates are limited to materials with a single refractive index, and there is a need for techniques that can efficiently create uniform laser-induced channels in multi-layer substrates with different material compositions.
Innovation Solution
A method using a pulsed laser system that directs a beam through a multi-layer substrate, employing self-focus damage volumes to create uniform laser-induced channels across the thickness of materials with varying refractive indices, by tailoring the focal energy distribution and accounting for non-linear self-focusing effects using ray tracing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a laser beam is directed through a multi-layer substrate with different refractive indices, then channels can be formed in multiple material layers, but the distribution of damage volumes becomes non-uniform due to varying self-focus effects
Solution Approach 1:
The patent applies local quality by adjusting the laser beam's focal energy distribution to match the specific optical properties of each material layer. By tailoring the energy distribution locally to account for varying refractive indices, the method achieves uniform damage volume distribution across different layers while maintaining the ability to process multi-layer substrates.
Solution Approach 2:
The patent employs parameter changes by modifying the laser beam's focal energy distribution parameters to compensate for the varying self-focus effects in different material layers. This involves adjusting energy distribution parameters based on the optical properties of each layer to maintain uniform damage volumes throughout the multi-layer substrate.
2Manufacturing precision
If the laser beam energy is concentrated to form uniform damage volumes, then channel quality improves, but the complexity of controlling focal energy distribution increases
Solution Approach 1:
The patent implements feedback by using ray tracing techniques to model and predict the focal energy distribution through multi-layer substrates. This computational feedback mechanism allows for pre-calculation of the optimal energy distribution pattern, reducing the need for complex real-time control adjustments while achieving uniform damage volumes.
Solution Approach 2:
The patent applies preliminary action by performing ray tracing calculations and determining the optimal focal energy distribution before the actual laser processing. This pre-planning of energy distribution based on substrate optical properties simplifies the real-time control requirements while ensuring uniform channel formation.
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 formation of uniform laser-induced channels in substrates with multiple layers of different materials, facilitating easy separation and maintaining a consistent appearance of the separation surface, even when dealing with materials of varying refractive indices and non-transparent laminating layers.
Implementation Method 1
forming a laser-induced channel that extends into the first material layer, the laser-induced channel comprising a uniform distribution of self-focus damage volumes
Data Source
AI summary
A laser system comprising a laser that produces a pulsed laser beam is configured to form a laser-induced channel in a multi-layer substrate including first and second material layers. The material layers may have different refractive indices. The laser-induced channel includes a uniform distribution of self-focus damage volumes through at least a portion of the thickness of one or both of the material layers. One of the material layers may be partially transparent or non-transparent. An optical assembly of the laser system can be configured to produce uniformly distributed self-focus damage volumes at an effective focal region corresponding to the substrate thickness. The distribution of damage volumes can be tailored to include areas or peaks of high damage volume density where it is desired to ablate material.