Optical Relay Layout for Telecentric Laser Beam Positioning

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Laser-processing systems face issues with telecentric errors and beam distortion due to the pivot point being located outside the scan lens entrance pupil, leading to undesirable beam clipping and positional errors at the workpiece.

Innovation Solution

A laser processing apparatus is designed with a movable optical relay system that relays the pivot point to the scan lens, maintaining telecentricity by adjusting the optical path length through the use of actuators and movable optical components, ensuring the beam rotates about a pivot point at or near the entrance pupil.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the scan lens is moved relative to the positioner, then the optical path length changes, but the pivot point moves outside the scan lens entrance pupil causing telecentric errors

Engineering Contradiction:

Improvescan lens movement capabilityVSAvoidbeam positioning accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

An optical relay system is introduced as an intermediary between the positioner and scan lens. This relay system includes optical elements (lenses and mirrors) that transfer the pivot point image from the positioner to the scan lens entrance pupil, maintaining the telecentric condition even when the scan lens moves relative to the positioner.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The optical relay system adds an intermediate optical dimension between the positioner and scan lens. By introducing this additional optical path with multiple elements, the system maintains the pivot point at the correct location while allowing mechanical movement in the original dimension.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Adaptability or versatility

If the optical path length changes, then the system becomes more adaptable, but beam distortion and clipping occur

Engineering Contradiction:

Improveoptical path adjustabilityVSAvoidbeam distortion and clipping

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The optical relay system acts as a mediator that maintains the pivot point image quality despite changes in optical path length. The relay optics compensate for path length variations to prevent beam distortion and clipping at the scan lens entrance pupil.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The optical relay system is designed to dynamically maintain the pivot point position at the scan lens entrance pupil even as the optical path length changes. This dynamic compensation prevents beam distortion and clipping while allowing optical path adjustment.

Inventive Principle:

Principle #15Dynamics

3Device complexity

If the pivot point is outside the entrance pupil, then the system structure is simpler, but telecentric errors are introduced

Engineering Contradiction:

Improveoptical system structureVSAvoidtelecentricity

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution maintains acceptable telecentricity and prevents beam clipping, enhancing the precision and accuracy of laser processing by stabilizing the beam's position at the workpiece.

Implementation Method 1

a first reflector having a first reflective surface, wherein the first reflector is arranged to receive the beam of laser energy propagating from the first positioner; an optical output: and a second reflector having a second reflective surface opposing the first reflective surface, wherein the first and second reflective surfaces are arranged and configured to relay the beam of laser energy received at the first reflector from the optical input to the optical output

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 2

a first lens arranged and configured to focus the beam of laser energy within the optical relay system, and a second lens arranged and configured to focus the beam of laser energy exiting the optical relay system, wherein the first lens and the second lens are configured to magnify the beam of laser energy

Methodology Applied

Scientific EffectFocusing: Focusing

Data Source

PatentUS20230390866A1Optical relay system and methods of use and manufacture

Publication Date: 2023.12.07 JPMORGAN CHASE BANK N A AS COLLATERAL AGENT

AI summary

Numerous embodiments of optical relay systems are disclosed. In one embodiment, a laser-processing apparatus includes an optical relay system configured to correct for beam placement errors by maintaining the optical path length of a beam of laser energy between a first positioner and a scan lens. In another embodiment, the optical relay system may include a first lens, a second lens, and a zoom lens assembly arranged between the first lens and the second lens, wherein the zoom lens assembly includes a first lens group and a second lens group. The zoom lens assembly may be movable relative to the first lens and the second lens (e.g., mounted on a positioner, such as a motion stage). The distance between the lenses of the first lens group and the distance between the lenses of the second lens group may be fixed or variable.