Laser Filament Guiding Angle for Precise Reel-to-Reel Ablation
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Solution Overview
Problem
Existing methods for preparing multilayer wires for electrochemical sensors face challenges in achieving high accuracy and production rate, particularly in maintaining signal-to-noise ratio and linearity, due to limitations in laser ablation processes and equipment service life.
Innovation Solution
A device and process that utilize a processing beam source, such as a laser, to ablate specific segments of multilayer wires with controlled filament orientation between 0 to 45 degrees, allowing for high-speed processing with minimal downtime and extended service life of the processing beam source, while maintaining precision and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-speed laser ablation is used to increase production rate, then productivity improves, but manufacturing precision deteriorates
Solution Approach 1:
The patent changes the orientation parameter of the filament from horizontal to inclined (0-45 degrees) during laser ablation. This parameter change allows the laser to process multiple layers of the multilayer wire simultaneously at high speed while maintaining precise control over the ablation depth and pattern, thereby preserving the signal-to-noise ratio of the electrochemical sensor even at high production rates
2Productivity
If continuous high-speed processing is used to increase productivity, then production rate improves, but reliability deteriorates
Solution Approach 1:
The patent employs periodic action by using pulsed laser ablation instead of continuous laser processing. The laser operates in controlled pulses that ablate material in discrete steps, allowing for brief intervals between pulses that reduce thermal accumulation and stress on the laser source. This periodic operation mode enables sustained high-speed processing while extending the service life of the laser beam source
Solution Approach 2:
The patent utilizes parameter changes by adjusting the laser pulse duration, frequency, and energy density to optimize both processing speed and laser source longevity. By carefully controlling these parameters, the system achieves high productivity through rapid pulsed ablation while preventing excessive thermal loading that would otherwise reduce the laser source service life
3Manufacturing precision
If high-precision laser ablation is used to improve manufacturing precision, then signal-to-noise ratio improves, but productivity deteriorates
Solution Approach 1:
The patent introduces a new dimension by tilting the filament at an angle of 0-45 degrees relative to the laser beam direction. This angular orientation allows the laser to ablate through multiple concentric layers of the multilayer wire in a single pass, effectively adding a dimensional component to the processing path. This enables high-precision ablation of all layers simultaneously, maintaining signal-to-noise ratio while dramatically increasing production rate compared to sequential layer removal
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 enables high-accuracy multilayer wires to be produced at a high production rate with reduced downtimes and extended service life of the processing equipment, ensuring improved signal-to-noise ratio and linearity of electrochemical sensors.
Implementation Method 1
high-precision laser ablation of the outer metal layer
Data Source
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AI summary
The invention relates to a device (100) for processing a filament (104) in a process stream (110), the device (100) comprising as components a) at least one processing beam source (105, 201), designed and arranged for emitting at least one processing beam (107, 202) which is suitable for processing a segment (108) of the filament (104) by interaction of the at least one processing beam (107, 202) with the segment (108) of the filament (104), thereby obtaining a processed filament (109); and b) a guiding means, comprising a filament feed which is i) arranged upstream of the at least one processing beam source (105, 201), and ii) designed to feed the filament (104) from a feed reel (101); wherein the guiding means is designed and arranged to guide the filament (104) so that during the processing the segment (108) of the filament (104) inclines an angle with a vertical axis in the range from 0 to 45°. Further, the invention relates to a process (400) for preparing a processed filament (109), to a processed filament (109) obtainable by this process (400) and to a use of a laser for processing a segment of a filament (104) in a reel-to-reel process.