Optical Lens for Deep Fine Hole Laser Processing
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Solution Overview
Problem
Existing optical systems face challenges in processing thin lines or cylindrical holes with large aspect ratios due to aperture limitations, resulting in diffuse spots or inadequate laser energy distribution.
Innovation Solution
An optical lens configuration comprising a positive plano-convex lens, a positive plano-convex lens with arc surfaces, and a negative meniscus lens, arranged coaxially to focus laser energy precisely, allowing for the processing of deep and thin features by varying the radii of curvature and central thicknesses of the lens surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the aperture is increased, then the laser energy is sufficient, but the processed thin lines or deep holes do not meet the size requirements
Solution Approach 1:
The optical lens is divided into three separate lens elements (first positive plano-convex lens, second positive plano-convex lens, and third negative meniscus lens) arranged in sequence. This segmentation allows each lens to contribute differently to the overall optical function, enabling independent optimization of energy concentration and spot size control that cannot be achieved with a single aperture adjustment.
Solution Approach 2:
The third surface of the second lens is designed with multiple arc surfaces having different focal points, creating local variations in optical properties. This allows different regions of the lens to focus light at different depths, enabling precise control of the focal spot characteristics while maintaining sufficient laser energy for processing deep features.
2Manufacturing precision
If the aperture is too small, then the processed features meet size requirements, but sharp diffuse spots appear and laser energy is insufficient
Solution Approach 1:
By segmenting the optical system into three lenses with specific focal lengths and arrangements, the system can maintain a small effective aperture for precision while the cumulative optical power of all three lenses ensures sufficient energy concentration. The negative meniscus lens specifically helps control diffraction effects that cause sharp diffuse spots.
Solution Approach 2:
The invention changes multiple optical parameters simultaneously: the focal lengths of the three lenses, the radii of curvature of their surfaces, and the distances between them. These parameter changes optimize the balance between aperture size, spot sharpness, and energy concentration, allowing small aperture operation without energy loss.
3Device complexity
If a single lens is used, then the structure is simple, but the optical system cannot process deep and thin features with large aspect ratios
Solution Approach 1:
The optical system is segmented into three lenses rather than using a single lens. This segmentation enables the system to achieve the complex optical function required for processing deep and thin features (large aspect ratio) by combining the effects of multiple lenses with different focal properties, which cannot be achieved with a single lens of reasonable complexity.
Solution Approach 2:
The second positive plano-convex lens acts as an intermediary element between the first and third lenses. Its third surface with multiple arc surfaces serves as a mediator that adjusts and refines the light path, enabling the transition from the initial beam shaping by the first lens to the final precise focusing by the third lens, thereby achieving deep feature processing capability.
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 optical lens effectively concentrates energy within a small aperture, enabling precise processing of features like 0.5 mm deep and 0.05 mm wide lines or holes, minimizing diffuse spots and ensuring accurate size requirements are met.
Implementation Method 1
An optical lens includes, successively coaxially arranged along a transmission direction of an incident light: a first lens being a positive plano-convex lens and having a first surface and a second surface; a second lens being a positive plano-convex lens and having a third surface and a fourth surface; and a third lens being a negative meniscus lens and having a fifth surface and a sixth surface
Implementation Method 2
the first surface and the third surface are convex surfaces against the transmission direction of the incident light; the fifth surface and the sixth surface are convex surfaces towards the transmission direction of the incident light
Data Source
AI summary
An optical lens comprising a first lens (L1), a second lens (L2), and a third lens (L3) that are sequentially arranged on a common optical axis in the transmission direction of an incident light. Both the first lens and the second lens are positive plano-convex lenses. The third lens is a negative meniscus lens. The first lens comprises a first curved surface (S1) and a second curved surface (S2). The second lens comprises a third curved surface (S3) and a fourth curved surface (S4). The third lens comprises a fifth curved surface (S5) and a sixth curved surface (S6). The two curved surfaces of each lens respectively are the light incident surface and the light exit surface of the lens. The first to the sixth curved surfaces are sequentially arranged in the transmission direction of the incident light. The first curved surface and the third curved surface protrude in reverse to the transmission direction of the incident light. The fifth curved surface and the sixth curved surface protrude in the transmission direction of the incident light. The third curved surface is constituted by connecting sequentially and directly multiple arced surfaces (Φ1, Φ2, Φ3, Φ4, and Φ5) having different focuses and all of the focuses (f1, f2, f3, f4, and f5) of these arced surfaces are located on the optical axis. The optical lens is applicable in processing deep and fine holes or engraving deep and fine lines.