Polygon Mirror Laser Perforation Beyond Galvo Scanner Speed Limits
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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 are inadequate for high-speed perforation requirements in aerostructure production.
Innovation Solution
A method utilizing a rotating polygon mirror with multiple faces to reflect and focus a laser beam for creating perforations on substrates, allowing for faster and more precise control over the perforation process, including the ability to define desired depths, perimeter configurations, and sizes of perforations.
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 flexibility in pointing control is achieved, but the process speed becomes too slow for aerostructure production
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 with multiple faces, each reflecting the laser to different positions on the substrate, eliminating the mechanical limitations of galvo scanners and achieving much higher process speeds while maintaining pointing control flexibility
Solution Approach 2:
The patent introduces dynamic rotation of the polygon mirror to achieve rapid beam positioning. The mirror rotates continuously at controlled speeds, allowing the laser beam to be dynamically directed to different locations on the substrate without the mechanical constraints of galvo scanners, thereby significantly increasing perforation process speed
2Quantity of substance
If multiple lasers are used in conjunction with a galvo-based scanner, then perforation capability is achieved, but the process remains slow
Solution Approach 1:
The patent replaces the slow galvo-based multi-laser system with a high-speed rotating polygon mirror that can direct a single laser beam to multiple positions rapidly. The rotational mechanism enables the laser to scan across the substrate and create multiple perforations at production-relevant speeds, maintaining perforation capability while dramatically improving productivity
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 on substrates, enabling efficient production of aerostructures by allowing for faster and more controlled perforation processes, improving both speed and accuracy compared to traditional methods.
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
Figure 1A~1C
Figure 1D~1E
Figure 2A
AI summary
Various arrangements and methods are disclosed for forming one or more perforations (12) on a substrate surface (22) using a laser system, at least one rotating polygon mirror (130), and at least one other mirror, which can be fixed or movable, e.g. a moving mirror (150) or another polygona mirror.. A rotating polygon mirror (130) is used to define a plurality of perforations in a row set or band (30) on a substrate surface (22) by incrementing (e.g., moving) a first mirror (150) between a plurality of fixed (e.g., pointing) positions.