Laser Output Modulator for Uniform Power Density
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Solution Overview
Problem
Current laser scribe systems experience uneven power density across the surface of a substrate due to the elliptical shape of the laser beam, leading to potential damage and reduced active area, particularly at the center compared to the edges.
Innovation Solution
A laser system with a diode-pumped solid-state laser and a laser output modulator that adjusts the power output and pulsing frequency in real-time based on the area of the laser beam spot, using a modulation apparatus connected to a central controller to maintain uniform power density across the substrate surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a laser beam is used to remove material from a surface, then material removal efficiency is improved, but uneven power density causes damage to the object
Solution Approach 1:
The patent applies dynamics by making the laser output power adjustable in real-time based on the beam spot area. The laser system transitions from a static power output to a dynamic one that adapts to changing beam spot areas during scanning, thereby maintaining uniform power density and preventing object damage while preserving material removal efficiency
Solution Approach 2:
The patent changes the laser output power parameter dynamically. By modulating the laser power according to the beam spot area at different positions, the system maintains constant power density across the scanned surface, resolving the contradiction between effective material removal and prevention of damage
2Manufacturing precision
If laser power is increased to improve scribe quality, then manufacturing precision is improved, but power density becomes too high causing damage
Solution Approach 1:
The patent dynamically adjusts the laser power parameter based on the beam spot area. This allows the system to maintain optimal power density for high-quality scribing without exceeding damage thresholds, as the power is modulated in real-time to match the local beam spot characteristics
3Manufacturing precision
If real-time modulation of laser output is implemented, then uniform power density is achieved, but device complexity increases
Solution Approach 1:
The patent implements a feedback control system where the laser output power is modulated based on measured or calculated beam spot area information. This feedback mechanism enables uniform power density distribution while maintaining relatively simple system architecture through direct coupling of the modulation apparatus to the laser driver
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 up to 40% modulation of laser output power, achieving uniform scribe lines and preventing damage by maintaining consistent power density, thereby enhancing precision and reducing substrate damage during the scribing process.
Implementation Method 1
A laser can be used to remove a portion of a material coating from a surface of an object
Implementation Method 2
A laser system with a diode-pumped solid-state laser
Data Source
AI summary
A laser system can include a laser and a laser output modulator to modulate the output of the laser.