Laser Surface Structuring for Uniform Large-Area Structural Color
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Solution Overview
Problem
Existing methods for forming fine periodic structures on surfaces using laser processing face challenges in achieving uniform structural colors over large areas due to variations in laser beam incident angles, which affect the pitch and quality of the periodic structure, especially when high-speed processing is required.
Innovation Solution
A method involving the use of pulse laser light to form fine periodic structures by setting adjacent regions on a substrate and controlling the scanning paths and positional relationships to ensure uniformity and continuity of the structure across larger areas, using a combination of optical deflection and mechanical movement to minimize angle variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the angle by which the optical deflection scanning is performed is increased to increase the processing range and processing speed, then the productivity is improved, but the variation of the incident angle depending on the position in the processing range increases, deteriorating the manufacturing precision of the periodic structure pitch
Solution Approach 1:
The processing area is divided into multiple small regions (first region and second region) arranged in the first direction. Each region is processed separately with controlled laser scanning, allowing the incident angle to be kept consistent within each region while maintaining overall large-area processing capability.
Solution Approach 2:
The laser beam scanning system dynamically adjusts the scanning parameters when transitioning between regions. The controller coordinates the deflection portion and movement mechanism to maintain appropriate incident angles throughout the entire processing range, adapting the scanning path to preserve pitch uniformity across different positions.
2Area of stationary object
If the processing range is increased to treat larger substrate areas, then the productivity is improved, but the variation of incident angle across the processing range increases, deteriorating the uniformity of structural color
Solution Approach 1:
The large processing area is segmented into multiple adjacent small regions. By processing each region separately with controlled laser parameters, the incident angle variation is minimized within each region, ensuring uniform structural color formation while covering large total areas through the combination of multiple regions.
Solution Approach 2:
Each small region is treated with locally optimized laser scanning parameters to ensure consistent incident angles and uniform periodic structure formation. The local processing quality is maintained across all regions, resulting in overall uniform structural color throughout the large processing area.
3Manufacturing precision
If the incident angle variation is reduced to maintain uniform periodic structure pitch, then the manufacturing precision is improved, but the processing range is limited, reducing the productivity
Solution Approach 1:
The substrate surface is divided into multiple small regions arranged in the first direction. Each region is processed with controlled laser scanning that maintains consistent incident angles, ensuring uniform periodic structure pitch. The segmentation allows precise control within each region while enabling extended total processing coverage through multiple regions.
Solution Approach 2:
Multiple scanning paths extending in the first direction are used to process each region, and multiple regions are arranged in the first direction. This dimensional arrangement allows the system to maintain small incident angle variations within each scanning path while covering large total areas through the combination of multiple paths and regions, effectively resolving the contradiction between precision 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 enables the formation of high-quality, uniform structural colors over large areas with improved productivity, ensuring that the boundaries between scanning regions are visually imperceptible, thereby enhancing the aesthetic appeal and effectiveness of decorative or anti-forgery applications.
Implementation Method 1
forming a fine periodic structure in a manner similar to self-organization by ablation of a portion where incident light and scattered light along the surface of the substrate interfere with each other
Implementation Method 2
forming a fine periodic structure in a manner similar to self-organization by ablation of a portion where incident light and scattered light along the surface of the substrate interfere with each other
Implementation Method 3
the scan is typically performed by deflecting the laser beam by using an optical scanning mechanism such as a galvano mirror
Data Source
AI summary
A product includes a fine periodic structure having a plurality of projection portions extending parallel to each other in a first direction in each of a first region and a second region adjacent in the first direction on a surface of a substrate. The fine periodic structure formed in an inner portion of the first region and the fine periodic structure formed in an inner portion of the second region are substantially the same periodic structures. End portions of the plurality of projection portions formed in the first region and end portions of the plurality of projection portions formed in the second region are formed in a boundary portion between the first region and the second region.