Laser Scribing System with Real-Time Optical Feedback
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Solution Overview
Problem
Current laser beam placement techniques accumulate positional tolerances, leading to inefficient spacing between features on a surface, particularly in manufacturing processes like solar panel production, where precise placement relative to previous entities is crucial to avoid overlap and maximize efficiency.
Innovation Solution
A laser beam focusing and deflection system with an optical detection system that provides real-time feedback to precisely place laser beams relative to existing entities on a surface, using non-contact methods to determine the position of previous features and adjust the beam's position accordingly, minimizing positional tolerance concerns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional laser beam placement techniques are used, then the manufacturing process is simple, but positional tolerances accumulate leading to inefficient spacing between features
Solution Approach 1:
The patent implements a feedback mechanism where the detection system continuously monitors the position of previously created features and provides real-time positional information to the laser placement system. This feedback loop enables dynamic adjustment of laser beam placement to compensate for accumulated tolerances, achieving precise relative positioning without requiring overly complex predetermined spacing calculations
Solution Approach 2:
The patent replaces traditional mechanical measurement and positioning methods with an optical detection system that uses light to non-contactly detect feature positions. This substitution eliminates mechanical wear and contact errors, providing more accurate and reliable positional data for the feedback control system
2Reliability
If increased spacing is used to accommodate positional tolerances, then overlap between features is prevented, but manufacturing efficiency decreases
Solution Approach 1:
By implementing real-time feedback from the detection system, the patent enables the laser placement system to dynamically adjust positioning based on actual feature locations. This allows features to be placed closer together with confidence that overlap will be prevented through active correction, thereby maintaining reliability while improving manufacturing efficiency
Solution Approach 2:
The patent transitions from static predetermined spacing to dynamic adaptive positioning. The system continuously adjusts laser beam placement in real-time based on detected feature positions, allowing optimal spacing that accommodates tolerances only where needed while maximizing manufacturing efficiency in other areas
3Measurement precision
If non-contact detection methods are used, then positional accuracy is improved, but device complexity increases
Solution Approach 1:
The patent designs the optical detection system to serve multiple functions: detecting feature positions, verifying placement accuracy, and providing feedback for control. This multi-functionality justifies the added complexity by eliminating the need for separate measurement and control systems, integrating detection and positioning into a unified system
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 placement of laser beams adjacent to previous features, reducing the need for increased spacing and enhancing manufacturing efficiency by maintaining desired offsets between features, thereby improving the operational efficiency of solar panels and other applications.
Implementation Method 1
using a laser beam focusing and deflection system to direct a laser spot onto a surface through an optical path
Implementation Method 2
laser beam focusing and deflection system to direct a laser spot onto a surface through an optical path
Implementation Method 3
an optical detection system provides reliable detection of the position of an existing entity on the surface as viewed through the optical path of the deflection system
Implementation Method 4
the laser beam scribe is focused to a 'waist' (or 'spot') that is scanned along the desired path of the scribe, removing some or all of the layers which make up the photovoltaic coating
Implementation Method 5
heating a surface (e.g., for printers), transmitting signals/data, and scribing (etching) or cutting a surface with a sufficiently powerful laser
Data Source
AI summary
Techniques are described for laser-scribing a feature on a surface in relation to a reference feature on that surface, such as a feature created by a previous placement of the laser beam. In particular, using a laser beam focusing and deflection system to direct a laser scribing spot onto a surface through an optical path, an optical detection system provides reliable detection of the position of an existing feature on the surface as viewed through the optical path of the deflection system. Based on feedback provided from the detection system to the deflection system, the position of the laser beam may be modified through the deflection system in relation to the viewed feature to scribe a subsequent feature on the surface which tracks the existing feature in real time. A method of scribing to accomplish the objectives is also disclosed.