Pulsed Laser Beam Scanning with Variable Acceleration Patterns
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Solution Overview
Problem
Existing laser scanning systems face limitations in controlling accelerations during faster scan rates, leading to reduced accuracy and increased mechanical stress, which restricts the creation of precise flaps in materials using pulsed laser beams.
Innovation Solution
A system and method that utilize compound scan patterns with varying accelerations, where a first pattern with higher acceleration is replaced by a second pattern with lower acceleration in high-acceleration regions, combined with blanking to prevent overlap and maintain constant scan rates, allowing for more precise control and reduced mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If faster scan rates are used, then productivity is improved, but manufacturing precision deteriorates due to acceleration-related errors and control accuracy loss
Solution Approach 1:
The patent applies dynamics by making the scan pattern adaptive and variable rather than fixed. The system dynamically adjusts scan parameters including switching between different scan patterns (spiral, raster, concentric circles) based on real-time conditions, and varies acceleration profiles during scanning to optimize both speed and precision. This dynamic adaptation allows the system to maintain manufacturing precision while operating at higher scan rates.
Solution Approach 2:
The patent implements parameter changes by modifying scan pattern parameters (acceleration, velocity, pattern type) during the scanning process. The system changes acceleration rates dynamically, switches between different mathematical patterns, and adjusts focal point separation based on position and material properties. These parameter variations enable the system to achieve high productivity while maintaining precision through optimized scanning trajectories.
2Productivity
If faster scan rates are used, then productivity is improved, but reliability deteriorates due to increased mechanical stress and system lag
Solution Approach 1:
The system uses dynamic scan pattern selection and acceleration profiling to maintain reliability at high scan rates. By adapting the scan pattern in real-time and adjusting acceleration based on position and material properties, the system avoids mechanical stress concentrations and maintains control accuracy even at increased productivity levels.
Solution Approach 2:
The patent applies preliminary action by pre-calculating and planning scan trajectories that account for mechanical constraints and material properties before scanning begins. The system prepares acceleration profiles and pattern selections in advance based on the desired scan area and material characteristics, enabling smooth transitions and preventing mechanical stress while maintaining high scan rates.
3Ease of operation
If spiral or raster patterns are used, then ease of operation is improved, but manufacturing precision deteriorates in certain regions due to high accelerations
Solution Approach 1:
The patent applies segmentation by dividing the scan area into different regions and applying different scan patterns to different portions. The system can switch between spiral patterns in some areas and raster or concentric circle patterns in others, allowing each region to be scanned with the most appropriate pattern for maintaining precision while keeping the overall system easy to operate with standardized control interfaces.
Solution Approach 2:
The system implements local quality by varying scan pattern characteristics locally across different regions of the material. Acceleration rates, pattern types, and focal point separations are adjusted based on local material properties and position within the scan area. This allows manufacturing precision to be maintained in high-acceleration regions while preserving the overall simplicity of operation through automated pattern selection.
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 reduces acceleration-related errors and increases scanning accuracy, enabling faster scan rates and more precise material processing while minimizing mechanical stress, thus improving the creation of flaps in materials.
Implementation Method 1
One example of photoalteration using pulsed laser beams is the photodisruption (e.g., via laser induced optical breakdown) of a material
Implementation Method 2
Examples of photoalteration of the material include, but are not necessarily limited to, chemical and physical alterations, chemical and physical breakdown, disintegration, ablation, vaporization
Data Source
AI summary
Systems and methods of photoaltering a region of a material using a pulsed laser beam. The method includes scanning the pulsed laser beam in a first portion of the region with a first pattern, scanning the pulsed laser beam in a second portion of the region with a second pattern, and separating a flap of the material at the region. The system includes a laser, a controller selecting at least first and second patterns, and a scanner operable in response to the controller. The first pattern has a first maximum acceleration associated with the second portion, and the second pattern has a second maximum acceleration associated with the second portion. The second maximum acceleration is less than the first maximum acceleration. The scanner scans the pulsed laser beam from the laser in the first portion with the first pattern and in the second portion with the second pattern.