Laser Workpiece Separation Using Offset Heating and Focusing Elements
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Solution Overview
Problem
Existing methods for laser machining of transparent workpieces face challenges in achieving high-quality separation with controlled geometry and reduced surface roughness, particularly in materials like glass and plastic.
Innovation Solution
A method involving a pulsed machining laser beam forming focusing elements that introduce material modifications along a predetermined advancing line, followed by a heating laser beam with a positional offset to the machining beam, which induces targeted crack formation for precise separation, ensuring a high-quality separating surface with controlled geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single laser beam is used for machining transparent material, then the process is simple, but the separation quality and surface geometry control are insufficient
Solution Approach 1:
The single laser beam is divided into multiple independent focusing elements (first, second, third focusing elements) that can be positioned at different locations and angles. This segmentation allows each focusing element to create specific material modifications at precise positions, enabling better control over separation quality and surface geometry while maintaining a relatively simple overall system configuration.
Solution Approach 2:
Different focusing elements are positioned to create material modifications with different local characteristics. The first focusing element creates modifications at a first position, the second at a second position, and the third at a third position, allowing different regions of the workpiece to have different local properties that collectively achieve high-quality separation with controlled geometry.
2Manufacturing precision
If multiple focusing elements are used to improve separation quality, then the manufacturing precision increases, but the device complexity increases
Solution Approach 1:
Multiple focusing elements are combined within a single laser beam system. The laser beam is split into multiple paths that converge to create different focusing elements, merging the functionality of multiple lasers into one unified system. This reduces device complexity compared to using separate laser sources while maintaining the manufacturing precision benefits of multiple focusing elements.
3Productivity
If the heating laser beam is positioned directly over the machining line, then the separation is direct, but the surface roughness increases
Solution Approach 1:
The heating laser beam is intentionally positioned asymmetrically relative to the machining line, creating a deliberate offset between the heating zone and the material modification zone. This asymmetric positioning allows the heating beam to follow the machining line for efficient separation while maintaining a controlled distance that prevents excessive heat concentration, thereby reducing surface roughness and improving finish quality.
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
The method achieves a high-quality separation with reduced surface roughness and controlled geometry by using a positional offset between the machining and heating laser beams, resulting in efficient material separation with improved precision.
Implementation Method 1
The workpiece comprises a material transparent to the machining laser beam... introducing the focusing elements into the material of the workpiece... Material modifications, arranged by the moving the focusing elements relative to the material along a machining surface, are formed in the material
Implementation Method 2
subjecting the material to a heating laser beam... The heating laser beam is moved relative to the material along a heating laser beam advancing line, thereby separating the material along the machining surface
Implementation Method 3
Material modifications, arranged by the moving the focusing elements relative to the material along a machining surface, are formed in the material. The machining surface protrudes with respect to a partial region of the workpiece in a preferred direction
Data Source
AI summary
A method for separating a workpiece includes providing a machining laser beam that forms a plurality of focusing elements, introducing the focusing elements into a material of the workpiece, and moving the focusing elements parallel to an advancing line relative to the material. Material modifications are formed in the material along a machining surface that protrudes with respect to a partial region of the workpiece in a preferred direction. The method further includes subjecting the material to a heating laser beam that is moved relative to the material along a heating laser beam advancing line, thereby separating the material along the machining surface. The heating laser beam advancing line runs parallel to and is spaced apart from the advancing line with a positional offset that is anti-parallel to the preferred direction. The positional offset is at least 10% and at most 50% of a diameter of the heating laser beam.