Laser Patterning of Coated Transparent Surfaces With Feedback Control
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Solution Overview
Problem
The existing methods for creating pattern figures on partially transparent components, such as those used in vehicle lighting, require high precision and are complex due to manufacturing tolerances and the need for controlled removal of layers, making them challenging to achieve uniformity and accuracy in geometric deviations and transparency.
Innovation Solution
A method utilizing laser processing to create pattern figures by measuring and transforming coordinates, applying laser radiation with a sensor system to ensure precise control and uniformity, allowing for defined size, geometry, and transparency on partially transparent components coated on a surface, using a fixing device, robot module, and short-pulse laser with a sensor array for energy control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If subsequent removal of layers is used to create pattern figures, then pattern figures can be produced on coated components, but high precision requirements and manufacturing complexity increase due to geometric deviations and transparency variations
Solution Approach 1:
The patent replaces mechanical layer removal methods with laser-based processing. The laser system directly creates pattern figures by interacting with the coating layers through optical fields, eliminating the need for mechanical subtraction processes and their associated precision and complexity issues
Solution Approach 2:
The patent changes the physical state and properties of coating layers using laser radiation parameters (energy density, pulse duration, wavelength). By controlling laser parameters, the process achieves precise pattern creation without the geometric deviations and transparency variations that plague mechanical removal methods
2Manufacturing precision
If controlled layer removal is performed to achieve uniform transparency, then pattern figures with defined transparency can be produced, but the process requires high precision control and becomes more complex
Solution Approach 1:
The patent implements feedback control by measuring the transparency of the component during laser processing and adjusting laser parameters in real-time. This closed-loop control system automatically compensates for variations and achieves uniform transparency without requiring complex manual control procedures
Solution Approach 2:
The laser processing system automatically adjusts its own parameters based on real-time measurements of the coating layers. The system self-regulates the energy input to achieve the desired transparency uniformity, eliminating the need for complex external control mechanisms
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 production of pattern figures with precise control over size, geometry, and transparency, ensuring uniformity and minimizing material damage, with online quality control and flexibility in design, allowing for varied geometric shapes and transparency settings.
Implementation Method 1
irradiating the coated first surface with laser radiation
Implementation Method 2
the subsequent removal of layers for planned backlighting
Implementation Method 3
measuring the laser radiation on a second surface of the component opposite the first surface using a sensor
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a method for producing at least one pattern figure (6) comprising several pattern elements (5) by means of a laser (8) in a component (1) coated on a first surface (20) that is at least partially transparent, comprising the following steps: - providing the component (1); - coating the component (1) on the first surface (20) with at least one layer (3, 4); - measuring the coated first surface (20) of the component (1) with first coordinates (x1n, y1n, z1n); - creating the at least one pattern figure (6) with second coordinates (x2n, y2n, z2n); - transforming the second coordinates (x2n, y2n, z2n) of the at least one pattern figure (6) into third coordinates (x3n, y3n, z3n) using the first coordinates (x1n, y1n, z1n) of the coated first surface (20) of the component (1); - Transforming the third coordinates (x3n, y3n, z3n) into control coordinates of the laser (8) and/or the component (1);- Irradiating the coated first surface (20) with laser radiation (13) from the laser (8) using the control coordinates; - Measuring the laser radiation (13) on a second surface (21) of the component (1) opposite the first surface (20) using a sensor (11); - Comparing the laser radiation (13) received by the sensor (11) with a reference value; and - Switching off the laser radiation (13) when the reference value is reached.