Multi-Laser Beam Scribing with Adjustable Spacing and Focus
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Solution Overview
Problem
Existing laser scribing equipment for thin-film solar cells lacks the capability to efficiently increase the number of scribing beams, leading to larger dead areas in sub-cells and reduced production efficiency.
Innovation Solution
A multi-laser beam focusing and scribing device with a following function, incorporating a beam splitter module, focusing lens module, DOE beam shaping lens, adjustment shafts, CCD vision module, and distance-measuring sensor, allowing for independent adjustment of laser spacing and focal length, and enabling simultaneous scribing with multiple lasers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of scribing beams is increased to improve production efficiency, then productivity increases, but device complexity increases
Solution Approach 1:
The patent combines multiple laser beams (2-16 beams) into a single integrated scribing device, allowing simultaneous scribing operations. The beam splitter module divides the laser beam into multiple sub-beams that can scribe multiple lines at once, thereby increasing production efficiency without proportionally increasing device complexity through modular integration
Solution Approach 2:
The scribing device is designed with multi-functionality to perform various scribing operations (P1, P2, P3 scribing steps) using the same device platform. The adjustable beam spacing and focal length allow the device to adapt to different scribing requirements and substrate sizes, making it a universal solution for thin-film solar cell manufacturing
2Manufacturing precision
If the number of scribing beams is increased to reduce dead area in sub-cells, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The patent employs DOE (diffractive optical element) beam shaping lenses to create specific beam profiles (flat-top or multiple spots) tailored for precise scribing. Each beam can be independently shaped and focused to achieve optimal scribing quality in different areas, reducing dead area in sub-cells through localized beam quality optimization
Solution Approach 2:
The patent replaces manual mechanical adjustment systems with electrically-powered adjustment shafts and automated control systems. The electrically-powered second adjustment shaft controls beam spacing, while the first adjustment shaft controls focal length, enabling precise positioning without complex mechanical mechanisms and improving scribing precision through automated control
3Productivity
If multiple scribing devices are integrated to increase scribing capacity, then productivity increases, but device complexity increases
Solution Approach 1:
The patent integrates multiple scribing functions into a single device by combining beam splitter modules, focusing lens modules, and DOE beam shaping lenses. This allows 2-16 beams to operate simultaneously within one device, achieving the capacity of multiple devices while reducing overall system complexity through unified integration
Solution Approach 2:
The patent utilizes spatial arrangement of multiple beams in different dimensions to increase scribing capacity. The beams are arranged and focused at different positions and angles, allowing simultaneous scribing of multiple lines across the substrate in a multi-dimensional configuration, thereby increasing capacity without simply stacking multiple devices
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 device achieves high-efficiency simultaneous scribing with precise control over laser positioning and focal length, reducing dead areas in sub-cells and improving the quality and efficiency of thin-film solar cell production.
Implementation Method 1
the beam splitter module is configured to split an incident laser beam into a plurality of sub-beams; and a beam splitter of the beam splitter module is an analyzing crystal or a beam-splitting mirror
Implementation Method 2
the focusing lens module is configured to focusing 2-16 beams
Implementation Method 3
the DOE beam shaping lens is configured to transform each of the plurality of sub-beams into a flat-top spot or multiple spots
Implementation Method 4
the distance-measuring sensor is configured to monitor a distance from a surface of a to-be-processed product to the DOE beam shaping lens in real time; wherein the distance-measuring sensor is a laser range-finder
Data Source
AI summary
A multi-laser beam focusing and scribing device with following function includes a beam splitter module, a focusing lens module, a first shaft, a diffractive optical element (DOE) beam shaping lens, a second adjustment shaft, a coaxial charge-coupled device (CCD) vision module, and a distance-measuring sensor. The first adjustment shaft is configured to adjust a focus position, and the second adjustment shaft is configured to adjust a spacing between scribed lines, and is electrically-powered. The beam splitter module is configured to split an incident laser beam into a plurality of sub-beams.