Polygon Mirror Laser Perforation for Faster Aerostructure Substrates
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Solution Overview
Problem
Existing laser/scanner perforation technologies for aerostructures are slow due to the limitations of galvo-based x-y scanners, which hinder efficient creation of perforations in materials like carbon fiber reinforced polymers and ceramics.
Innovation Solution
A system utilizing a rotating polygon mirror with multiple faces to reflect and direct a laser beam for creating perforations on substrates, allowing for faster and more precise control over the perforation process, including depth, size, and configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a galvo-based x-y scanner is used to control laser beam direction, then flexible pointing control in two planes is achieved, but the process speed for creating perforations becomes relatively slow
Solution Approach 1:
The patent replaces the mechanical galvo scanner system with a polygon mirror system that uses rotational motion to deflect the laser beam. The polygon mirror rotates at high speed to scan the laser across the substrate, eliminating the mechanical limitations of galvo scanners and achieving much higher process speeds while maintaining two-plane control capability through coordinated rotation and beam steering.
Solution Approach 2:
The patent introduces dynamic rotational motion of the polygon mirror to achieve rapid beam scanning. The mirror rotates continuously at high angular velocities, dynamically directing the laser beam across different positions on the substrate. This dynamic approach replaces the step-by-step mechanical positioning of galvo scanners with continuous high-speed scanning, dramatically increasing productivity.
2Productivity
If a rotating polygon mirror is used to reflect the laser beam, then the speed of perforation creation is significantly enhanced, but the device complexity increases
Solution Approach 1:
The patent makes the polygon mirror system multi-functional by using it for both high-speed scanning and precise positioning. The same rotating polygon mirror that provides rapid scanning also enables controlled beam steering to different locations on the substrate. This eliminates the need for separate scanning and positioning mechanisms, reducing overall system complexity despite the sophisticated optical requirements.
Solution Approach 2:
The patent changes the operational parameters of the optical system by using a rotating polygon mirror that can vary its rotational speed and angular position. This allows the system to adapt between high-speed scanning modes and precise positioning modes, providing both high productivity and control flexibility without requiring multiple dedicated components for each function.
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 significantly enhances the speed and precision of perforation creation, enabling efficient processing of aerostructure materials, improving aerodynamic properties and surface conditioning.
Implementation Method 1
A laser beam is reflected from a face of the rotating first polygon mirror
Implementation Method 2
The laser beam ultimately impacts a substrate to remove material from the substrate
Data Source
AI summary
Various arrangements and methods are disclosed for forming one or more perforations on a substrate surface using a laser system, at least one rotating polygon mirror, and at least one other movable mirror. A rotating polygon mirror may be used to define a plurality of perforations in a row set or band on a substrate surface by incrementing (e.g., moving) a first mirror between a plurality of fixed (e.g., pointing) positions. A rotating polygon mirror may be used to define a plurality of perforations in a row set or band on a substrate using a first mirror that is maintained in a fixed (e.g., pointing) position. A first rotating polygon mirror and a second rotating polygon mirror may be used to define a plurality of perforations in a row set or band on a substrate surface, where the first and second polygon mirrors are used to define an extent of a given perforation in two dimensions on the substrate.