Laser Pattern Replication for Large-Area Precision Marking
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Solution Overview
Problem
Existing laser technologies are limited in their ability to form large images or numerous marks on materials like glass due to constraints in light energy and size, particularly in high-speed production environments such as the agrifood, pharmaceutical, and electronic sectors.
Innovation Solution
A method involving the repetition of a pattern on the surface or in the volume of a material using a coherent light beam, where the beam is shaped and focused to form non-overlapping patterns, allowing for extended image formation and increased number of marks without being limited by the laser source characteristics or material properties, utilizing a system with a source, optical modulation device, and focusing device to achieve this.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a coherent light beam is used to form marks on material surface, then marking precision is improved, but the number of marks and image size are limited by maximum light energy per pulse
Solution Approach 1:
The patent divides the light beam into multiple sub-beams using a diffraction grating, where each sub-beam forms a separate mark. This segmentation allows multiple marks to be created simultaneously from a single beam, increasing the number of marks beyond what a single beam could produce while maintaining marking precision.
Solution Approach 2:
The patent introduces spatial distribution of marks through the diffraction grating, arranging marks in a two-dimensional pattern rather than sequential one-dimensional marking. This dimensional expansion allows forming images with many more marks within the same pulse energy constraints.
2Quantity of substance
If laser power is increased to form more marks, then number of marks is improved, but damage threshold of modulation device is exceeded
Solution Approach 1:
Instead of concentrating all energy into fewer high-power marks, the system segments the beam into multiple lower-energy sub-beams. Each sub-beam carries a fraction of the total energy, allowing many marks to be formed simultaneously without exceeding the damage threshold of optical components.
Solution Approach 2:
The diffraction grating creates multiple copies of the beam profile at different spatial locations. Each copy (sub-beam) is a reduced-energy version of the original beam, enabling parallel mark formation without requiring high power at each location, thus protecting modulation devices from damage.
3Area of stationary object
If image size is increased to cover larger surface area, then coverage area is improved, but maximum image size is limited by laser characteristics
Solution Approach 1:
The patent uses a diffraction grating to distribute marks across a two-dimensional surface area, expanding from traditional one-dimensional linear marking. This allows forming large-area images with many marks simultaneously, overcoming the size limitations of conventional laser marking systems.
Solution Approach 2:
By segmenting the beam into multiple sub-beams arranged in a spatial pattern, the system can cover a larger surface area with a single pulse. The segmented structure allows parallel marking across extended areas without requiring multiple sequential pulses, thus increasing image size flexibility.
4Productivity
If high speed production rate is required, then productivity is improved, but existing laser technologies reach their limit
Solution Approach 1:
The patent creates multiple sub-beams from a single laser source using a diffraction grating, enabling simultaneous formation of multiple marks in one pulse. This parallel processing capability dramatically increases the number of marks per unit time, achieving high-speed production rates while maintaining large numbers of marks.
Solution Approach 2:
The system maintains continuous high-speed operation by forming all marks in parallel within each pulse cycle, eliminating sequential delays. The diffraction-based parallel marking allows the useful action of marking to continue at maximum speed without interruption for repositioning or sequential processing.
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 the formation of larger images and more marks on materials like glass without the limitations of traditional laser technologies, enhancing production efficiency and flexibility in high-speed industrial applications.
Implementation Method 1
forming the pattern on the surface or in the volume of the part by shaping and focusing a coherent light beam
Implementation Method 2
The invention relates to the field of laser processing of materials, of glass in particular
Implementation Method 3
marking or micromachining, for processing an image on the surface or in the volume of a material
Data Source
AI summary
The invention relates to a method for creating an image on a surface or in a volume of a part (9), the image comprising a repetition of a pattern (11), the method comprising the following steps: —creating the pattern (11) on the surface or in the volume of the part (9) by shaping and focusing a coherent beam (8A), the pattern comprising at least two local contrast maxima; —carrying out a cycle of the following steps at least once: —moving the beam and the part relative to one another, and —creating the pattern (11) on the surface or in the volume by shaping and focusing the beam such that the patterns created do not overlap. The invention also relates to a system for creating an image on a surface or in a volume of a part using the method.