Laser Line Optics With Offset Caustics for Stable Work-Plane Focus
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Solution Overview
Problem
Existing devices for generating a laser line on a work plane require complex mechanical adjustments of telescope lenses, which can lead to wear and tear and misalignment due to thermal lens formation, limiting the process window and increasing mechanical tracking requirements.
Innovation Solution
The device positions the caustics of the first and second laser beams offset in the illumination direction, eliminating the need for mechanical adjustment of optical elements along the short axis, thereby increasing the process window and depth of field, and reducing mechanical wear and tear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If mechanical adjustments of telescope lenses are used to maintain focus, then the process window can be adapted, but mechanical wear and tear increases and misalignment occurs due to thermal lens formation
Solution Approach 1:
The patent replaces the mechanical adjustment system with an optical design featuring two beam paths with offset caustics. Instead of mechanically moving lenses to adapt the process window, the system uses the optical arrangement where the first and second caustics are positioned at different locations, allowing process window adaptation through optical configuration rather than mechanical movement, thereby eliminating wear and thermal misalignment issues
Solution Approach 2:
The patent divides the single beam path into two separate beam paths (first beam path and second beam path), each with its own optical elements and caustic position. This segmentation allows independent optimization of each path and enables the system to maintain focus stability while adapting the process window through the combined effect of offset caustics, without requiring mechanical adjustments
2Manufacturing precision
If mechanical adjustment mechanisms are implemented to compensate for focal drift, then focus can be maintained, but device complexity and mechanical tracking requirements increase
Solution Approach 1:
The patent eliminates mechanical adjustment mechanisms by using an optical arrangement with two beam paths having offset caustics. The system maintains focus precision through the optical design where the first and second caustics are positioned at different locations, allowing the workpiece to remain within the process window without any mechanical movement or adjustment, thereby reducing device complexity and eliminating mechanical tracking requirements
Solution Approach 2:
Instead of using mechanical adjustments to compensate for focal drift after it occurs, the patent inverts the approach by pre-configuring the optical system with offset caustics that inherently accommodate focal variations. The offset caustic positions are designed beforehand to ensure the workpiece remains within the process window, eliminating the need for reactive mechanical compensation
3Adaptability or versatility
If optical elements are made adjustable to maintain beam profile, then process adaptability improves, but mechanical wear and thermal lens effects worsen
Solution Approach 1:
The patent replaces adjustable mechanical optical elements with a fixed optical arrangement featuring two beam paths with offset caustics. The beam profile control is achieved through the optical configuration itself rather than mechanical adjustment, eliminating the generation of thermal lenses that would occur with mechanical actuators and maintaining process adaptability through the offset caustic design
Solution Approach 2:
The patent extracts the adjustment function from mechanical components and embeds it into the optical design through offset caustic positioning. By taking out the need for mechanical adjustment and incorporating the adaptability directly into the optical arrangement, the system maintains beam profile control without generating thermal lens effects from mechanical actuators
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 configuration maintains the workpiece within the process window without mechanical readjustment, even with focal drift, and simplifies production and maintenance by allowing the optical elements to remain stationary, thus enhancing the beam profile's stability and reducing thermal lens effects.
Implementation Method 1
an optical arrangement having a first beam path which takes the first raw laser beam and reshapes the latter along a first optical axis to form a first illumination beam with a first caustic and a first beam profile
Implementation Method 2
having a second beam path which takes the second raw laser beam and reshapes the latter along a second optical axis to form a second illumination beam with a second caustic and a second beam profile
Implementation Method 3
the first and the second illumination beam being directed with overlap on the work plane and thus defining a joint illumination direction, the first and the second beam profile jointly forming the laser line on the work plane
Data Source
AI summary
A device for generating a laser line on a work plane includes a first laser light source configured to generate a first raw laser beam, a second laser light source configured to generate a second raw laser beam, and an optical arrangement configured to reshape the first raw laser beam to form a first illumination beam with a first caustic and a first beam profile, and reshape the second raw laser beam to form a second illumination beam with a second caustic and a second beam profile. The first illumination beam and the second illumination beam are directed with overlap on the work plane and define a joint illumination direction. The first beam profile and the second beam profile jointly form the laser line on the work plane. The optical arrangement is configured to position the first caustic and the second caustic offset from one another in the illumination direction.