Wire Surface Micro-Patterning With Bessel Beam Laser Sintering
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Solution Overview
Problem
Current methods for forming micro-patterns on wires with curvature, such as for microelectrode sensors, face challenges in durability and precision due to the need for adhesive coatings and pre-produced electrode patterns, which limit the ability to create precise patterns on small scales and are not suitable for wires with curvature.
Innovation Solution
A method involving the application of a nanoparticle solution to the wire followed by Bessel beam laser irradiation to induce sintering, allowing for direct formation of micro-patterns on the wire surface with a long depth of focus, enabling uniform thickness and precise pattern creation on curved wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a pre-produced electrode pattern is attached to the wire using adhesive coating, then the wire can be equipped with functional electrodes, but the durability of the electrode pattern becomes poor and the wire diameter increases
Solution Approach 1:
The patent combines the electrode pattern formation process with the wire manufacturing process itself. Micro-patterns are directly formed on the wire surface through laser irradiation during the wire drawing process, eliminating the need for separate adhesive coating and pattern attachment steps. This integration resolves the contradiction by achieving both ease of manufacture (through process integration) and reliability (through direct bonding to the wire surface).
Solution Approach 2:
The patent replaces the mechanical adhesive bonding system with a direct laser-based sintering or ablation system. Instead of using adhesive coatings to attach pre-made patterns, the invention uses laser energy to directly create functional micro-patterns on the wire surface, eliminating the adhesive layer and improving both durability and precision.
2Ease of manufacture
If a pre-produced electrode pattern is attached to the wire, then electrodes can be formed on the wire surface, but the manufacturing precision on a scale of several microns to tens of microns is limited
Solution Approach 1:
The patent replaces mechanical photolithography and adhesive-based pattern transfer methods with laser-based direct writing. The laser system can achieve sub-micron precision in forming micro-patterns directly on the wire surface, overcoming the resolution limits of conventional mechanical attachment methods while maintaining ease of manufacture through direct process integration.
Solution Approach 2:
The patent changes the fundamental parameter of pattern formation from mechanical attachment to laser-induced material modification. By controlling laser parameters (power, speed, wavelength) and wire parameters (drawing speed, tension), the system achieves high-precision micro-pattern formation that is not possible with conventional adhesive-based methods.
3Ease of manufacture
If conventional coating methods are used to form patterns on wire surface, then the entire surface can be coated, but forming precise microelectrode patterns on curved wire surface is difficult
Solution Approach 1:
The patent replaces conventional mechanical coating methods with laser-based direct writing. The laser system can precisely follow the curved wire surface geometry and deposit or remove material only in the desired micro-pattern locations, achieving high precision on curved surfaces while maintaining ease of manufacture through the flexibility of laser programming.
Solution Approach 2:
The patent introduces dynamic coordination between the wire feeding system and laser positioning system. As the wire moves through the system, the laser dynamically adjusts its position and focus to maintain precise patterning on the curved wire surface, enabling high-precision microelectrode formation that adapts to the wire's geometry in real-time.
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 method enables the formation of microelectrode patterns on wires with diameters ranging from several tens to hundreds of micrometers, improving durability and precision, and facilitating the creation of micro-sensors that can be inserted into small spaces like blood vessels, such as flow rate and temperature sensors.
Implementation Method 1
a step of irradiating the nanoparticle solution layer with a Bessel beam laser to induce sintering of nanoparticles, thereby forming a micro-pattern on the surface of the wire
Implementation Method 2
irradiating the nanoparticle solution layer with a Bessel beam laser to induce sintering
Data Source
AI summary
A method for producing a micro-pattern on surface of a wire is disclosed. The method includes a step of applying a nanoparticle solution to the wire to form a nanoparticle solution layer on the surface of the wire; and a step of irradiating the nanoparticle solution layer with a Bessel beam laser to induce sintering of nanoparticles, thereby forming a micro-pattern on the surface of the wire. It is possible to form a microelectrode pattern on a level of several to tens of micrometers on the surface of a micro-wire having a diameter on a scale of several tens to several hundreds of micrometers. Since a laser optical system with a long depth of focus is used, a micro-pattern with a uniform thickness can be formed on surface of a wire having a curvature in a simple.