Non-Circular Laser Beam for Conductive Track Sintering
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Solution Overview
Problem
Existing methods for forming conductive tracks on substrates face challenges in achieving accurate and efficient irradiation of deposited material while minimizing thermal damage, requiring improved resolution and speed to enhance manufacturing efficiency.
Innovation Solution
A method using a laser beam with a non-circularly symmetric energy distribution, directed by a controller and scanning system, to accurately irradiate deposited material along a path on a substrate, ensuring efficient formation of conductive tracks while reducing thermal damage to surrounding areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a laser beam is used to irradiate deposited material to form conductive tracks, then the electrical conductivity is improved, but thermal damage to surrounding areas occurs
Solution Approach 1:
The patent applies local quality by creating a non-uniform energy distribution within the laser beam cross-section, where the intensity varies across different regions. This allows the beam to deliver higher energy density to the deposited material for effective sintering while reducing energy in surrounding areas to minimize thermal damage, thus achieving localized effective irradiation.
Solution Approach 2:
The patent employs asymmetry by using a laser beam with non-circularly symmetric energy distribution. The intensity profile is deliberately made asymmetric or elliptical rather than circular, allowing optimized energy concentration in specific directions or regions of the deposited material, thereby improving sintering efficiency while controlling thermal spread to adjacent areas.
2Productivity
If the laser beam irradiation speed is increased to improve manufacturing efficiency, then productivity is improved, but irradiation accuracy deteriorates
Solution Approach 1:
The patent applies dynamics by making the laser beam characteristics adjustable and adaptable. The beam's energy distribution, shape, and intensity can be dynamically modified to match the specific requirements of different deposition patterns and processing speeds, allowing high-speed operation without sacrificing accuracy through real-time optimization of beam parameters.
Solution Approach 2:
The patent utilizes parameter changes by varying the laser beam's energy distribution parameters, such as intensity profile, beam width, and focal position. By adjusting these parameters according to the processing requirements, the system maintains irradiation accuracy even at higher speeds, effectively resolving the trade-off between speed and precision.
3Device complexity
If a conventional circularly symmetric laser beam is used, then the device complexity is low, but the irradiation efficiency and accuracy are insufficient
Solution Approach 1:
The patent introduces asymmetry into the laser beam's energy distribution to improve irradiation efficiency and accuracy. By using non-circularly symmetric intensity profiles, the beam can be optimized to match the geometry and thermal properties of the deposited material, achieving better processing results without requiring complex additional optical systems.
Solution Approach 2:
The patent modifies the laser beam parameters, specifically the energy distribution pattern, to enhance irradiation performance. By changing from a conventional circular symmetric profile to a customized non-symmetric profile, the system achieves improved accuracy and efficiency while maintaining relatively simple device architecture through software or optical parameter control rather than hardware complexity.
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 allows for high-speed, accurate formation of conductive tracks with reduced thermal damage, improving manufacturing efficiency and the quality of electrical connections.
Implementation Method 1
A method uses a laser beam having a non-circularly symmetric energy distribution within a cross-sectional area of the laser beam incident on the surface to accurately irradiate deposited material
Implementation Method 2
The directed laser beam can sinter dried electrically conductive precursor materials to form a cured solution providing increased electrical conductivity
Data Source
Figure 1
Figure 2a~2f
Figure 3a~3b
AI summary
The present invention provides a method for forming a conductive track on a surface (21) of a substrate (11). The method comprises providing a substrate (11), wherein the substrate (11) comprises deposited material (23) along a path on a surface (21) of the substrate (11). Generating a laser beam having an optical axis and an energy distribution within a cross-sectional area of the laser beam incident on the surface (21). The energy distribution of the laser beam is non-circularly symmetric about the optical axis at the surface (21). The method further comprises directing the laser beam to move along said path to irradiate the deposited material (23) to provide a conductive track along said path. A selected orientation of the energy distribution within the cross-sectional area is aligned with the direction of movement of the laser beam.