Laser Multi-Point Pattern Switching for Mismatched Processing Grids
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Solution Overview
Problem
Existing laser processing systems face challenges in maintaining high throughput when the number of rows and columns of a processing area do not align with the number of rows and columns of a multi-point pattern, leading to inefficient use of laser light and increased time for DOE replacement and fluence adjustment.
Innovation Solution
Incorporation of a light shielding plate and a second actuator to selectively shield rows and columns of a multi-point pattern, allowing for the selection of different patterns to align with the processing area requirements, and a laser processing processor to control the movement and selection of these patterns for each step position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of rows and columns of the processing area does not align with the number of rows and columns of the multi-point pattern, then the throughput decreases and time is lost for DOE replacement and fluence adjustment, but using a fixed multi-point pattern leads to inefficient use of laser light
Solution Approach 1:
The patent divides the multi-point pattern into selectable subsets by introducing a light shielding plate that can block specific rows and columns. This segmentation allows the system to use only the necessary portion of the laser light pattern for the given processing area size, avoiding waste of laser energy on unnecessary points while maintaining high throughput.
Solution Approach 2:
The patent makes the light shielding plate movable and controllable, allowing dynamic adjustment of which rows and columns are shielded. This dynamic capability enables the system to adapt the multi-point pattern to different processing area dimensions in real-time, eliminating the need for DOE replacement and fluence readjustment while optimizing laser light usage.
2Manufacturing precision
If the processing area dimensions do not match the multi-point pattern dimensions, then DOE replacement and fluence readjustment are required, but these operations reduce productivity
Solution Approach 1:
The patent creates a virtual selection of different multi-point patterns by using a light shielding plate to block portions of a single multi-point pattern. This copying approach allows the system to simulate multiple pattern configurations without physically replacing the DOE, thereby maintaining pattern alignment precision while avoiding productivity loss from replacement operations.
Solution Approach 2:
The patent changes the effective pattern parameters by selectively shielding rows and columns of the multi-point pattern. This parameter adjustment allows the system to adapt to different processing area dimensions by modifying which laser points are active, eliminating the need for DOE replacement and fluence readjustment while maintaining precise pattern alignment.
3Adaptability or versatility
If a light shielding plate is added to selectively shield rows and columns, then pattern adaptability improves, but device complexity increases
Solution Approach 1:
The patent introduces a light shielding plate as an intermediary element between the multi-point pattern source and the workpiece. This intermediary component enables pattern adaptability by selectively blocking laser beams, providing versatility without requiring complex modifications to the core optical system or laser source.
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
Maintains high throughput by optimizing the use of laser light patterns even when the processing area dimensions do not match the multi-point pattern dimensions, reducing the need for DOE replacement and fluence readjustment.
Implementation Method 1
a diffractive optical element configured to divide first laser light into a plurality of beams of second laser light
Implementation Method 2
a light concentrating optical system configured to generate a multi-point pattern in which a plurality of concentration spots are arranged in a grid-like manner in a row direction and a column direction by concentrating the plurality of beams of second laser light
Data Source
AI summary
A laser processing apparatus includes a diffractive optical element dividing first laser light into beams of second laser light and output the second laser light, a light concentrating optical system generating a multi-point pattern in which concentration spots are arranged in a grid-like manner, a first actuator moving a workpiece, a light shielding plate capable of shielding at least one row and at least one column of the multi-point pattern, a second actuator changing a relative position of the light shielding plate with respect to the multi-point pattern so as to select one of first to fourth multi-point patterns, and a laser processing processor controlling the first actuator to move the workpiece such that any one of the first to fourth multi-point patterns is radiated to each step position and controlling the second actuator to select one of the first to fourth multi-point patterns for each step position.