Laser Scoring of Metal-Polymer Structures via Selective Absorption
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Solution Overview
Problem
Existing methods for scoring multi-layer structures with metal and polymer layers require multiple lasers, which are cumbersome, lack precision, and are sensitive to environmental changes, making them inefficient and difficult to maintain.
Innovation Solution
A single laser beam with a wavelength that is absorbed by the metal layer but not the polymer layer is used to score through both layers, leveraging the energy plume generated by the metal absorption to create a score line, ensuring precise and consistent scoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple lasers are used to score metal and polymer layers simultaneously, then both layers can be scored, but the device complexity increases and precision decreases due to alignment difficulties
Solution Approach 1:
The patent combines the functions of multiple lasers into a single laser system that can score both metal and polymer layers. The single laser replaces multiple separate laser systems, merging their scoring functions while maintaining the ability to process different materials with different absorption properties.
Solution Approach 2:
The single laser system is designed to perform multiple functions: scoring polymer layers and scoring metal layers, which previously required different specialized lasers. This multi-functional approach eliminates the need for separate laser systems while maintaining effectiveness for both material types.
2Reliability
If two laser lines are required to overlap to form a common cut, then both metal and polymer layers can be scored, but the stability decreases due to sensitivity to environmental changes
Solution Approach 1:
The patent merges the scoring operation into a single laser line that processes both metal and polymer layers simultaneously, eliminating the need for two separate laser lines to overlap. This single-line approach removes the alignment instability caused by environmental factors such as temperature changes and humidity variations.
3Manufacturing precision
If CO2 laser power is increased to cut through metal layers, then metal can be scored, but the production speed decreases and fine features cannot be achieved
Solution Approach 1:
The patent changes the laser operating parameters, specifically using a wavelength that metal layers absorb effectively. This parameter change allows the laser to score metal layers at normal production speeds without requiring excessive power increases, thereby maintaining both fine feature capability and productivity.
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 precise and efficient scoring of multi-layer structures with improved production speed and reduced maintenance, achieving better quality and consistency compared to using multiple lasers.
Implementation Method 1
A single laser beam, the laser beam having a wavelength for absorption by the metal and having little or no absorption by the first polymer layer, is used to score the multi-layer film structure
Implementation Method 2
leveraging the energy plume generated by the metal absorption to create a score line
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
A method of scoring a multi-layer film structure 10, wherein the multi-layer film structure comprises a metal layer 30 and polymer layer 40 bonded to each other, the method comprises using a single laser beam incident to the polymer layer 40 to produce a score line 160 in the polymer layer, wherein the laser energy is absorbed only by the metal layer 30.