Laser Shield Tunnel Separation for Brittle Molded Articles
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Solution Overview
Problem
Manufacturing molded articles from hard and brittle materials like glass, quartz, and silicon carbide is challenging due to their difficulty in being processed into desired shapes, and existing laser-based methods are time-consuming.
Innovation Solution
A method involving the formation of a shield tunnel and separation layer using laser beams to separate a workpiece into desired shapes, including a pore and modified regions, followed by a crack formation and relative movement to facilitate separation and division of the molded article.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If each substrate is irradiated with a laser beam to be molded into a desired shape, then a molded article having a fine shape can be manufactured, but the manufacturing takes time
Solution Approach 1:
The patent divides the workpiece into multiple sheets along the thickness direction by forming separation layers, allowing parallel processing of multiple substrates simultaneously. This segmentation enables batch manufacturing while maintaining fine shape precision through the shield tunnel structure formed by laser irradiation.
Solution Approach 2:
The shield tunnel structure is formed in advance within each sheet by laser irradiation before separation. This preliminary action creates a modified region with pores that facilitates clean separation and maintains shape precision during subsequent division, eliminating the need for time-consuming post-processing of each individual substrate.
2Productivity
If multiple sheets are separated by forming separation layers through laser irradiation, then batch processing efficiency is improved, but the complexity of the laser processing system increases
Solution Approach 1:
The laser processing system is designed to perform multiple functions: forming shield tunnels within sheets, creating separation layers between sheets, and enabling subsequent division. This multi-functionality allows batch processing of multiple substrates simultaneously without requiring separate processing systems, improving productivity while managing complexity.
Solution Approach 2:
The patent introduces the thickness direction as an additional processing dimension by forming separation layers at specific depths within the workpiece. This dimensional approach allows multiple sheets to be separated and processed in parallel, significantly improving batch processing efficiency without substantially increasing system complexity.
3Reliability
If a shield tunnel structure is formed by laser irradiation, then clean separation is achieved, but the processing time for each substrate increases
Solution Approach 1:
The workpiece is segmented into multiple sheets through separation layers formed by laser irradiation. This segmentation allows the total processing time to be distributed across multiple substrates processed in parallel, reducing the effective processing time per substrate while maintaining clean separation quality through the shield tunnel structure.
Solution Approach 2:
The laser processing parameters are optimized to form the shield tunnel structure with specific pore characteristics and modified regions. By adjusting laser power, scanning speed, and pulse duration, the process achieves clean separation with high reliability while minimizing the energy input and processing time required for each substrate.
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 efficient and time-effective production of molded articles with complex shapes by reducing the need for individual substrate irradiation, thereby enhancing processing speed and efficiency.
Implementation Method 1
forming, along the desired shape, a shield tunnel including a pore extending from the first surface of the workpiece to a predetermined depth in a thickness direction of the workpiece and a modified region surrounding the pore by positioning a concentration region of a first laser beam having a wavelength transmissive to the workpiece inside the workpiece and irradiating the workpiece with the first laser beam along the desired shape
Implementation Method 2
forming a separation layer including a modified portion parallel to the first surface and a crack extending from the modified portion by positioning a concentration point of a second laser beam having a wavelength transmissive to the workpiece at a depth corresponding to a thickness of the molded article to be manufactured from the first surface, relatively moving the concentration point and the workpiece, and irradiating the workpiece with the second laser beam
Data Source
AI summary
A method for manufacturing a molded article having a desired shape from a workpiece includes: forming a shield tunnel including a pore extending from a surface of the workpiece to a predetermined depth in a thickness direction and a modified region surrounding the pore by positioning a concentration region of a first laser beam inside the workpiece and irradiating the workpiece with the first laser beam along the desired shape; forming a separation layer including a modified portion parallel to the first surface and a crack extending from the modified portion by positioning a concentration point of a second laser beam at a depth corresponding to a thickness of the molded article, relatively moving the concentration point and the workpiece, and irradiating the workpiece with the second laser beam; separating the workpiece into first and second workpieces; and dividing the molded article from the first workpiece along the shield tunnel.