Annular Vortex Laser Micro-Hole Drilling in Thick Glass
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Solution Overview
Problem
Existing methods for forming micro-holes in glass-based objects are limited by their inability to achieve high accuracy, precision, and throughput, especially when requiring a high density of micro-holes.
Innovation Solution
A micro-hole-forming system that converts a conventional Gaussian laser beam into an annular vortex laser beam with a larger depth of focus, allowing for the formation of micro-holes in glass-based objects using either a one-step ablation process or a two-step method involving irradiation and etching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional Gaussian laser beams are used to form micro-holes, then the process can be simple, but the depth of focus is limited and manufacturing precision deteriorates
Solution Approach 1:
A phase device is introduced as an intermediary component between the Gaussian laser beam source and the glass-based object. This phase device transforms the conventional Gaussian beam into an annular vortex beam with enhanced depth of focus, thereby improving micro-hole formation precision without requiring direct modification of the laser source itself
Solution Approach 2:
The invention changes the beam parameters by transforming a standard Gaussian beam into an annular vortex beam with topological charge. This parameter transformation results in a significantly enlarged depth of focus (at least 1.1× larger, potentially up to 10× larger), which directly improves manufacturing precision for micro-hole formation in glass-based objects
2Manufacturing precision
If high density of micro-holes is required, then product quality improves, but processing time increases and productivity deteriorates
Solution Approach 1:
The annular vortex beam maintains a continuous and stable intensity distribution along its propagation path within the extended depth of focus region. This continuity allows for uninterrupted processing of high-density micro-hole patterns without requiring frequent refocusing or repositioning, thereby maintaining high productivity while achieving high micro-hole density
3Manufacturing precision
If larger depth of focus is achieved, then manufacturing precision improves, but beam intensity may be reduced
Solution Approach 1:
The transformation to an annular vortex beam configuration fundamentally changes the energy distribution parameters. The beam redistributes its energy in an annular pattern with a singularity at the center, maintaining high peak intensity at the annular region while extending the depth of focus. This parameter change allows simultaneous achievement of large depth of focus and sufficient beam intensity for effective micro-hole formation
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 system enables the rapid and precise formation of micro-holes with diameters ranging from tens of microns to hundreds of microns and depths up to several millimeters, maintaining panel strength and allowing for high throughput.
Implementation Method 1
a beam-forming system configured to convert a conventional Gaussian laser beam into a vortex laser beam having an annular cross-sectional shape and that has a larger depth of focus than the corresponding conventional Gaussian diffracted beam
Implementation Method 2
The annular vortex beam is used to form micro-holes in a glass-based object using either a one-step or a two-step method. In the one-step method, the annular vortex beam has sufficient energy to form a hollow cylindrical region in the body of the glass-based object via ablation of the glass-based material
Data Source
AI summary
The systems and methods disclosed herein utilize a beam-forming system configured to convert a Gaussian laser beam into an annular vortex laser beam having a relatively large depth of focus, which enables the processing of thick or stacked glass-based objects annular laser beam is defined in part by a topological charge m that defines an amount of rotation of the annular vortex beam around its central axis as it propagates annular vortex beam is used to form micro-holes in a glass-based object using either a one-step or a two-step method micro-holes formed by either process can be in the form of recesses or through-holes, depending on the application size of the micro-holes can be controlled by controlling the size of the annular vortex beam over the depth of focus range.