Phase-Compensated Laser Drilling for Inclined Hole Precision
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Solution Overview
Problem
Existing laser drilling techniques face challenges in achieving efficient and precise drilling of inclined holes, particularly in the context of thinner and lighter 3C devices, high-frequency communications, and 4K image transmission, due to issues with laser beam deformation and uneven energy distribution.
Innovation Solution
A laser processing device and method that utilize a compensation system with a phase compensation sheet to correct the phase difference of the laser beam, combined with an imaging system that includes primary and secondary focusing components, to ensure precise focusing of the laser beam on the workpiece, even at non-zero angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser beam is used for inclined drilling, then drilling efficiency is improved, but beam pattern distortion occurs due to non-zero angle incidence
Solution Approach 1:
The patent applies preliminary action by pre-compensating the laser beam phase distribution before the beam reaches the workpiece. A phase compensation sheet is positioned in the optical path to pre-correct the beam pattern distortion that would otherwise occur during inclined drilling, allowing the beam to maintain proper focus and energy distribution even at non-zero incidence angles
Solution Approach 2:
The patent changes the phase parameter of the laser beam by introducing a phase compensation sheet with specific optical properties. This sheet modifies the phase distribution of the beam to counteract the distortion caused by inclined incidence, effectively transforming the beam parameters to compensate for the non-zero angle effect
2Manufacturing precision
If phase compensation sheet is introduced to correct beam distortion, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent uses an intermediary element - the phase compensation sheet - placed between the laser source and the workpiece. This intermediary component performs the phase correction function without requiring complex active control systems or multiple optical elements, thereby improving precision while minimizing the increase in device complexity
3Manufacturing precision
If imaging system with multiple optical components is used, then beam focusing precision is improved, but device complexity increases
Solution Approach 1:
The patent merges the imaging system with the beam delivery system by integrating multiple optical components (objective lens, tube lens, and phase compensation sheet) into a unified optical path. This combination achieves precise focusing at the processing position while reducing the overall system complexity compared to separate imaging and beam delivery systems
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 solution effectively prevents processing beam pattern distortion, simplifies the control mechanism, reduces process errors, improves processing quality, and increases fabrication speed by ensuring a linear relationship between the phase compensation sheet shifting and processing depth.
Implementation Method 1
The compensation system includes a phase compensation sheet configured to force the laser beam spreading away from the optical axis to form a beam pattern, wherein the phase compensation sheet is designed based on the non-zero angle
Implementation Method 2
The imaging system includes a first optical component configured to primary focus the beam pattern
Implementation Method 3
a second optical component configured to secondary focus the primary focused beam pattern to transform the beam pattern into a processing beam focusing on a processing position
Data Source
AI summary
A laser processing device includes a laser beam source, a compensation system, and an imaging system. The laser beam source is configured to provide a laser beam, in which a non-zero angle is defined between an optical axis of the laser beam and a normal direction of the surface of the workpiece. The compensation system includes a phase compensation sheet. The phase compensation sheet is configured to force the laser beam spreading away from the optical axis thereby forming a beam pattern, and the phase compensation sheet is designed based on the non-zero angle. The imaging system is configured to transform the beam pattern to a processing beam that focuses on a processing position, and a distance from the phase compensation sheet to the laser beam source along the optical axis is decided according to a processing depth of the processing position. A laser processing method is also disclosed.