Laser Trim Cut Pulse-Rate Control for Precise Resistance Tuning
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Solution Overview
Problem
Laser trimming of electronic components for precise resistance tuning faces challenges in maintaining accuracy and control as cuts lengthen, leading to increased manufacturing costs due to extended trim times and the need for additional cuts.
Innovation Solution
A method involving controlled laser cutting with varying pulse rates and translation speeds to form multiple cut portions in electronic components, including a first high pulse rate for the second cut portion to induce instability, followed by a lower pulse rate for precise termination, enhancing accuracy and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additional trim cuts are added to enhance accuracy, then trim cut accuracy is improved, but manufacturing cost increases due to extended trim time
Solution Approach 1:
The patent applies dynamics by varying the laser pulse rate during different stages of the trimming process. The pulse rate is increased during the second cut portion to induce controlled instability that enhances cut accuracy, then decreased during the final cut portion to allow precise termination. This dynamic adjustment of process parameters enables high accuracy without requiring multiple separate trim cuts, thereby reducing total trim time and manufacturing cost.
Solution Approach 2:
The patent changes the laser pulse rate parameter throughout the trimming process to optimize different stages. By transitioning from a first pulse rate to a higher second pulse rate and then to a lower third pulse rate, the process achieves enhanced accuracy through controlled instability while maintaining efficient processing speed, avoiding the need for additional trim cuts and extended manufacturing time.
2Manufacturing precision
If laser trimming control is maintained as cut length increases, then cut accuracy is preserved, but control stability is lost and trimming becomes unmanageable
Solution Approach 1:
The patent resolves the stability-accuracy contradiction by dynamically adjusting the pulse rate based on the trimming stage. During the second cut portion, a higher pulse rate induces controlled instability that enhances cut accuracy. During the final cut portion, the pulse rate is reduced to restore control stability and enable precise termination. This dynamic parameter adjustment maintains both accuracy and controllability throughout the extended trim process.
Solution Approach 2:
The patent uses periodic variation of the pulse rate to manage control stability throughout the trimming process. By alternating between different pulse rates in different cut portions, the system periodically adjusts the level of control aggressiveness, allowing enhanced accuracy during intermediate stages while maintaining stability for precise final termination.
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 achieves enhanced trim cut accuracy with reduced processing time and cost by stabilizing the laser control loop at key stages, allowing for precise resistance adjustments without excessive trimming.
Implementation Method 1
The laser cutting tool is configured to remove material from a feature of an electronic component
Data Source
AI summary
A method of fabricating an electronic component includes: controlling a laser cutting tool at a first pulse rate to form a first cut portion in a feature of the electronic component, the feature having opposite first and second sides spaced apart from one another along a first direction, and third and fourth sides spaced apart from one another along a second direction, the first cut portion extending from the third side toward the fourth side; controlling the laser cutting tool at a higher second pulse rate and to form a second cut portion extending from the first cut portion toward the fourth side; and controlling the laser cutting tool at a third pulse rate to form a final cut portion extending from the second cut portion toward the fourth side, the third pulse rate less than the second pulse rate.