Laser Roller Surface Structuring With Split-Beam Fluence Control
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Solution Overview
Problem
Existing methods for enlarging the irradiated processing field on a roll surface using laser ablation become increasingly complex and inefficient due to the limitations of beam shaping, which hampers the ability to achieve a larger irradiated area without compromising the efficiency of beam-shaping optical elements.
Innovation Solution
A method utilizing a device with a laser source, beam shaper, beam splitter, and focusing unit, where the beam shaper and splitter interact to redistribute the laser intensity, concentrating energy in specific areas for efficient material removal while minimizing energy input in other areas, thereby increasing the irradiated area and achieving optimal fluence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If beam shaping is used to increase the irradiated processing field, then the irradiated area is enlarged, but the efficiency of beam-shaping optical elements decreases
Solution Approach 1:
The laser beam is divided into multiple separate beams using beam splitters, with each beam independently shaped by beam formers to create multiple intensity patterns on the roller surface. This segmentation allows each optical element to operate at optimal efficiency while collectively covering a larger processing area
Solution Approach 2:
The patent creates multiple copies of the laser beam through beam splitters, where each copied beam is then independently focused and shaped to produce identical or varied intensity patterns at different locations on the roller surface, effectively multiplying the processed area without compromising individual beam quality
2Area of stationary object
If complex beam shaping is applied to increase the irradiated area, then the processing field is enlarged, but the system complexity increases
Solution Approach 1:
The system divides the complex task of covering a large area into simpler sub-tasks by splitting the beam into multiple separate beams, each handled by simpler optical elements. This segmentation reduces the complexity burden on each individual component while achieving the overall goal of large-area processing
3Area of stationary object
If energy is distributed over a larger area, then the irradiated area increases, but the energy input per area (fluence) decreases
Solution Approach 1:
The patent applies local quality by creating distinct intensity patterns where different regions of the roller surface receive different energy densities. Beam formers concentrate energy in specific local areas to achieve optimal fluence for material removal, while other areas receive minimal or no energy, allowing large-area processing with optimized energy distribution
Solution Approach 2:
By segmenting the total energy into multiple separate beams, each beam can be independently optimized to deliver appropriate fluence to its target area. This prevents energy dilution that would occur with a single large-area beam, as each segmented beam maintains sufficient intensity for effective processing
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 allows for a larger irradiated area on the roll surface with optimal energy input, enhancing material removal efficiency and enabling complex surface structuring by redistributing radiation intensity, resulting in a more effective and efficient processing method.
Implementation Method 1
wherein the structuring is carried out by laser ablation
Data Source
Figure 1~2(b)
Figure 3~4
AI summary
An apparatus for structuring a roller surface is proposed, when the apparatus has a laser source and an optical system, wherein the laser source is embodied to generate laser pulses, wherein the optical system has at least one beam shaper, at least one beam splitter and a focusing unit, wherein the combination of beam shaper and beam splitter is disposed between the laser source and the focusing unit.