Wedge Prism Laser Beam Steering for Micro-Arc Patterning
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Solution Overview
Problem
Existing laser processing methods struggle with high motor acceleration and deceleration requirements and image distortion when forming small circular arcs or curves, particularly for patterns with diameters less than or equal to 0.05 mm, leading to reduced service life and precision issues.
Innovation Solution
A method and device utilizing a pair of wedge prisms and motors to control laser focus, allowing for precise circular arc and curve tracking without the need for galvanometer systems, by rotating and adjusting the distance between the prisms to form patterns directly on the material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a galvanometer system is used to control laser beam deflection for processing small circular arcs, then the laser can follow curved trajectories, but the motor requires high acceleration and deceleration speeds which shortens service life and causes temperature rise and image distortion
Solution Approach 1:
The patent replaces the galvanometer's mechanical mirror deflection system with a spatial light modulator (SLM) that uses optical phase modulation to control laser beam direction. The SLM divides the circular arc trajectory into multiple discrete points, and the laser sequentially scans these points under computer control, eliminating the need for high-speed mechanical acceleration and deceleration while maintaining circular arc processing capability
Solution Approach 2:
The continuous circular arc trajectory is segmented into multiple discrete scanning points. Instead of requiring continuous high-speed mechanical deflection, the system controls the laser to sequentially hit these predetermined points, transforming a continuous mechanical motion problem into a discrete positioning problem that reduces motor stress and eliminates temperature-induced drift
2Manufacturing precision
If the polygon side length is reduced to draw smaller circular arcs, then the circular arc shape precision improves, but the acceleration and deceleration frequency increases causing temperature rise and image distortion
Solution Approach 1:
The patent replaces the mechanical galvanometer system with an SLM-based optical control system. The computer calculates and stores the coordinates of discrete points on the circular arc in advance, and the SLM controls the laser to sequentially scan these points. This eliminates the mechanical acceleration and deceleration processes that cause temperature rise and zero point drift, while maintaining high circular arc accuracy through precise digital positioning
3Manufacturing precision
If hardware upgrades such as improving angle sensor resolution or using digital signal control are implemented, then the processing precision may improve, but the device complexity and cost increase significantly
Solution Approach 1:
The patent replaces complex mechanical precision systems (high-resolution angle sensors, digital signal controllers, active cooling systems) with a simpler SLM-based optical modulation system. The precision is achieved through computer-calculated coordinate storage and optical phase control rather than through complex mechanical hardware, thereby reducing device complexity and cost while maintaining or improving processing accuracy
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
Enables high-precision laser processing of small circular arcs and curves with diameters less than 0.05 mm, reducing motor stress and improving processing accuracy while eliminating the need for complex hardware upgrades.
Implementation Method 1
uses focused high-energy laser beam to irradiate materials, and through the photo-thermal electric effect in the space range where the energy density of the beam is higher than the damage threshold value of the material (such as: Gasification evaporation, electron avalanche and so on) to ablate and remove the material
Implementation Method 2
A pair of wedge prisms and motors are used to control the focus of the laser
Implementation Method 3
utilizing a pair of wedge prisms and motors to control laser focus, allowing for precise circular arc and curve tracking
Data Source
AI summary
A method for cutting a material using a laser beam, comprising: providing a first wedge prism (310) and a second wedge prism (320) on a propagation path of a laser beam (10), and enabling the laser beam to enter the first wedge prism at an incident angle greater than 0 degree and less than 90 degrees and then to enter the second wedge prism at an incident angle greater than 0 degree and less than 90 degrees; focusing, by using a focusing wedge prism (400), the laser beam emitted from the second wedge prism and then applying the focused laser beam on a material (20); and deviating the position of the second wedge prism relative to the first wedge prism, and then forming a laser processing pattern on the material.