Laser Beam Intensity Shaping for Precise Thermal Processing
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Solution Overview
Problem
Existing laser processing methods lack precise control over the local intensity distribution of laser radiation, limiting the ability to achieve desired temperature and processing profiles on workpiece surfaces.
Innovation Solution
An apparatus and method that modulate the intensity of laser beams using elements in the beam path and actuation of radiation sources, allowing for a defined, locally adjustable intensity distribution on the workpiece surface, enabling targeted thermal processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single laser beam with Gaussian intensity distribution is used, then the apparatus is simple, but the local intensity distribution cannot be precisely controlled
Solution Approach 1:
The patent divides a single laser beam into multiple separate beams using beam splitting elements. Each beam can be independently focused to create multiple focal spots on the workpiece surface, enabling localized intensity control in different regions. This segmentation approach transforms a single Gaussian distribution into multiple controllable intensity zones.
Solution Approach 2:
The patent introduces optical elements such as beam splitting cubes, dichroic mirrors, and focal length adjusting lenses as intermediaries in the beam path. These elements mediate between the laser source and the workpiece, allowing precise control over beam intensity distribution, focal positions, and spatial arrangement without modifying the laser source itself.
2Manufacturing precision
If multiple laser beams are used to achieve local intensity control, then the processing precision is improved, but the apparatus complexity increases
Solution Approach 1:
The patent designs the beam splitting and focusing system to be universally applicable for different processing configurations. The same optical elements can generate varying numbers of focal spots depending on the arrangement, and the system can adapt to different workpiece geometries and processing requirements without requiring completely different apparatus configurations.
Solution Approach 2:
The patent employs adjustable focal length lenses that can dynamically change the focusing characteristics of each beam. This dynamic adjustment capability allows the system to optimize focal spot sizes and positions in real-time, providing flexible control over the intensity distribution pattern without adding more static optical components.
3Temperature
If the intensity distribution is fixed by the Gaussian profile, then the laser source is simple, but the temperature distribution control is insufficient
Solution Approach 1:
The patent creates different intensity characteristics at different locations on the workpiece surface by positioning multiple focal spots at specific locations. Each focal spot can be optimized for local processing requirements, with the ability to concentrate energy where needed and reduce intensity in other areas, thereby achieving precise temperature distribution control.
Solution Approach 2:
The patent deliberately creates asymmetric intensity distributions by positioning focal spots non-uniformly across the workpiece surface. This asymmetric arrangement allows tailoring the temperature profile to match specific processing requirements, such as creating heat gradients for directional material flow or concentrating energy at specific defect locations.
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 allows for efficient and flexible control of temperature distributions on the workpiece surface, enabling precise processing profiles and increased processing options such as additive manufacturing, cutting, and surface structuring.
Implementation Method 1
a laser beam emitted by at least one radiation source
Implementation Method 2
the energy introduced by the laser radiation brings about the sought-after change in the material
Data Source
AI summary
An apparatus and a method for thermal processing within a processing region (1) at a workpiece surface (2) by means of a laser beam (6) emitted by at least one radiation source (5). Arranged in the beam path of the laser beam (6) between the at least one radiation source (5) and the processing region (1) on the workpiece surface (2), there is at least one element (10, 11, 12) by means of which the intensity of the laser beam (6) is modifiable in a locally defined manner within the processing region (1). As an alternative or in addition thereto, the intensity of at least one of the laser beams (6) is modifiable in a locally defined manner within the processing region (1) by a defined actuation of the plurality of radiation sources (5) such that a locally defined distribution of the intensity of the laser beam (6) striking the workpiece surface (2) is achievable within the processing region (1).