Roll-to-Roll Laser Film Patterning with a Reciprocating Suction Table
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Solution Overview
Problem
Ultrashort pulse lasers are not suitable for fiber transmission due to fiber breakage and laser change, making it difficult to ensure processing accuracy and quality when used with a roll form film supply, especially in laser processing machines with multiple processing heads.
Innovation Solution
A laser processing machine that includes a suction table, drive mechanism, unwinding and winding devices, and irradiation units to hold and reciprocate a roll-shaped film while using a spatial transmission method for ultrashort pulse lasers, with suction units to absorb bending and maintain film stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an ultrashort pulse laser is transmitted by space transmission method, then processing quality is improved, but optical path length becomes long and processing head reciprocation becomes difficult
Solution Approach 1:
Instead of moving the processing head to perform reciprocating processing, the patent inverts the approach by moving the film itself through the stationary processing head. The film is fed from a roll, unwound, and conveyed in the reciprocating direction, allowing the processing head to remain fixed while still achieving patterning on the moving film.
Solution Approach 2:
The patent replaces the mechanical reciprocation system with a film conveyance system. Instead of mechanically moving the processing head back and forth, a film conveyance mechanism (including feed rolls and unwind reels) is introduced to move the film through the stationary processing head, simplifying the optical path while maintaining processing capability.
2Productivity
If the film is fed in roll form, then continuous processing is improved, but film bending and positional deviation occur
Solution Approach 1:
The patent introduces a film conveyance mechanism that includes feed rolls and unwind reels positioned before the processing head. This mechanism pre-companies and stabilizes the film in the reciprocating direction, cushioning against bending and positional deviations that would otherwise occur during roll-to-roll processing, thereby ensuring consistent processing quality.
Solution Approach 2:
The patent changes the operational parameters by introducing a controlled film conveyance system that regulates film tension and positioning. By controlling the feed rate and tension through the conveyance mechanism, the film is maintained in a stable state during processing, preventing bending and deviation while enabling continuous roll-form processing.
3Productivity
If multiple processing heads are arranged, then productivity is improved, but space requirement becomes limited
Solution Approach 1:
The patent transitions from arranging multiple processing heads in the horizontal direction (consuming lateral space) to arranging them in the vertical direction (utilizing vertical space). The film is conveyed vertically through the processing heads, allowing multiple heads to be stacked without increasing the horizontal footprint, thereby improving productivity while maintaining a compact arrangement.
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 high-accuracy and efficient patterning processing on roll-form films using ultrashort pulse lasers by maintaining film stability and preventing meandering and positional deviations, ensuring consistent processing quality.
Implementation Method 1
a suction table having a suction port formed on an upper surface side and configured to hold the target film in a flat state by suction
Data Source
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AI summary
A laser processing machine for performing laser processing on a target film to be processed while feeding a film wound in a roll shape. The laser processing machine includes a suction table having a suction port formed on an upper surface side and configured to hold the target film in a flat state by suction, a drive mechanism configured to cause the suction table to reciprocate in a film conveyance direction, an unwinding device located upstream of the suction table in the film conveyance direction and configured to hold the film, a winding device located downstream of the suction table in the film conveyance direction and configured to wind up the target film after being processed, and a plurality of first irradiation units configured to irradiate a target surface to be processed of the target film held by suction by the suction table with a laser beam.