Uniform Laser Heating for Precise 3D Material Transfer
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Solution Overview
Problem
Existing image forming apparatuses face challenges in accurately attaching high-viscosity materials such as inks and conductive pastes to desired positions without scattering, particularly with methods like inkjet and Laser-Induced Forward Transfer (LIFT) using Gaussian laser beams, which lead to clogging, resolution degradation, and inaccurate positioning.
Innovation Solution
A flying body generating method and apparatus that uses a uniformly heated laser beam with an approximately uniform temperature distribution above the melting point of the target material to reduce intermolecular forces, allowing precise attachment of flying target materials without scattering, using a uniformly heating laser beam to generate a uniformly heated region at the interface between the base and target materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If Gaussian laser beams are used for LIFT method, then the flying target material can be propelled to desired positions, but the material scatters and attachment precision deteriorates
Solution Approach 1:
The patent changes the fundamental parameter of laser beam intensity distribution from Gaussian (high intensity at center, low at edges) to uniform intensity distribution across the beam cross-section. This parameter change ensures that all portions of the flying target material receive equal energy, preventing edge effects that cause scattering and maintaining precise attachment at desired positions.
Solution Approach 2:
The invention applies uniform energy distribution across the entire cross-section of the laser beam, ensuring that every local region of the flying target material receives identical energy input. This eliminates local variations in heating that would otherwise cause differential expansion and scattering, achieving consistent attachment precision across the entire material surface.
2Reliability
If high-viscosity materials are used, then material functionality is improved, but material flow control becomes difficult and positioning accuracy deteriorates
Solution Approach 1:
The patent utilizes phase transition (melting) of the flying target material through uniform laser heating. The uniform intensity distribution ensures that high-viscosity materials melt uniformly across their entire surface, reducing viscosity temporarily to enable controlled flow and precise positioning, then solidifying upon cooling to maintain the desired shape and position.
3Use of energy by moving object
If laser beam energy is concentrated at the center, then energy efficiency is improved, but edge regions are underheated and material uniformity deteriorates
Solution Approach 1:
The patent fundamentally changes the intensity distribution parameter of the laser beam from Gaussian concentration to uniform distribution. This ensures that edge regions receive the same energy density as central regions, achieving uniform heating and melting across the entire flying target material surface, which is critical for maintaining material composition uniformity during the LIFT process.
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 method effectively suppresses scattering and ensures accurate attachment of high-viscosity materials, maintaining resolution and throughput by using a uniformly heated laser beam to control the direction and placement of flying target materials.
Implementation Method 1
irradiating a base material from a surface thereof opposite to a surface including a flying target material in at least a part of the surface, with a laser beam in a manner that a uniformly heated region having an approximately uniform temperature distribution higher than or equal to a melting point of the flying target material is generated at an interface between the base material and the flying target material
Implementation Method 2
a uniformly heated region having an approximately uniform temperature distribution higher than or equal to a melting point of the flying target material is generated
Data Source
Figure 1A~3A
Figure 3B~4C
Figure 4D~4F
AI summary
Provided is a flying body generating method including a flying target material flying step of irradiating a base material (411, 512, 551, 741, 851, 1543, 1611) from a surface thereof opposite to a surface including a flying target material (421, 751, 853, 1612) in at least a part of the surface, with a laser beam (431, 433, 711, 812, 813, 1532, 1603) in a manner that a uniformly heated region having an approximately uniform temperature distribution higher than or equal to a melting point of the flying target material is generated at an interface between the base material and the flying target material, to fly the flying target material in an irradiating direction of the laser beam.