FILTERING PATTERN FOR LASER BEAMS SUITABLE FOR THE PRODUCTION OF SUPERCAPACITORS

A method and apparatus comprising a manufacturing process, equipment and a product. The manufacturing process and equipment configured to produce very high precision parts using a laser beam. Embodiments of the manufacturing process and equipment provide an improved method for the production of supercapacitors with critical dimensions on the order of one to fifty microns that can store electricity at very high energy densities using a modified laser beam. Using the manufacturing process and equipment, the proposed improvements allow the production of key parts thousands of times faster than what can be achieved using the usual process, resulting in a manufacturing time suitable for mass production.

FIELD OF THE INVENTION

The present invention is related to a method and apparatus comprising a manufacturing process, equipment for the production of a product, and a product. The manufacturing process and equipment configured to produce very high precision parts using a laser beam. Embodiments of the manufacturing process and equipment provide an improved method for the production of supercapacitors with critical dimensions on the order of one to fifty microns that can store electricity at very high energy densities using a modified laser beam. Using the manufacturing process and equipment, the proposed improvements allow the production of key parts thousands of times faster than what can be achieved using the usual process, resulting in a manufacturing time suitable for mass production.

BACKGROUND

Laser beams have been extensively applied in many different areas in the manufacture of all sorts of small and big parts made of a wide variety of materials. Lasers have been proved as both reliable and precise and, in many areas, quickly evolved to become the industry standard method to produce a part or component.

Lasers offer many advantages allowing the user to select different levels of power, wavelength, pulse duration and width of the beam to achieve the desired result, whether it is a cut, an engraving, material removal, cleaning, drilling. welding, and many other options. Laser sources of all sorts of characteristics in terms of power, wavelength, modulation, advanced optics and control systems have been perfected and are now available off the shelf allowing a laser beam to be generated according to the needs of a particular process and be positioned with accuracy at relatively high speeds matching the demands for most applications.

The production of very high precision parts however poses a daunting challenge that has so far not been met by the available laser manufacturing processes. In particular, the production of a supercapacitors using materials such as graphene requires an extremely high number of very thin tracks with width and depth dimensions of less than fifty microns to be cut out of a graphene slab.

The tracks form a structure of two electrodes each one with a very high number of intertwined fringes that support an electrolyte and that are made as thin as possible so that more fringes can be accommodated in a given volume to as required produce a high-performance supercapacitor. The cuts required to separate adjacent fringes must be very precise and leave no undesired remains that could produce short circuits in the finished structure. The cuts also need to be done gently and in a controlled manner to avoid damaging the delicate structure rendering it less accessible to the electrolyte that in turn would result in negative impacts on the performance of the device.

This means a laser beam used to do the job cannot use more than a certain amount of power per unit area limiting the cutting speed and the depth of the cut. As it is advantageous to use thick slabs to increase the amount of active material in the supercapacitor the limitations in cut speed and depth result in a compound problem for manufacturing time. A very narrow beam of limited power thin enough to cut the fringes apart to form each electrode must be made to follow a very precise path that in most cases may have a total combined length of hundreds of thousands of meters to produce the number of required fringes within the three-dimensional volume of the graphene or other conductive material of only a few centimeters. Additionally, this beam must pass exactly over the same path many times to achieve the goal of a clean cut along each channel and all the way through the bottom of the slab. Depending on the size of the structure several hours or even days may be required to produce the parts needed. This is not practical for mass production of affordable devices.

An obvious possibility is to use multiple laser beams, but this is not easy and causes serious problems. The alignment of the multiple individual beams must be perfect; a single misaligned beam may result in produced parts with impaired performance and the problem can very easily reach a point that the parts become inoperative. As the requirements for both beam positioning precision and beam movement speed tend to push the limits of the laser positioning system this becomes even more challenging as high speeds tend to introduce some jitter in the effective beam positioning.

Another problem is maintenance. As the positioning system is required to operate constantly near its limits for extended periods of time, normal wear and tear may result in frequent need to realign the beams and periodic replacement of affected components resulting in down time for maintenance and increased operational costs.

Using advanced optics to split a laser beam into multiple parallel beams is also not satisfactory. An optical device able to produce thousands of perfectly parallel beams is difficult to construct and expensive to buy. The optic design parameters need to be very narrowly adjusted to the laser wavelength, power, etc. resulting in only one fixed beam configuration. Many different optics may be required to produce all the features in a part design and integrating all these pieces with the required level of precision in a streamlined production line is very difficult. The fact that these multiple beam optic devices can only do one job for one specific part results in poor flexibility as a manufacturer is requested to produce many different components for different applications requiring therefore an excessive number of custom devices and custom production lines with correspondent cost impact.

Even if a solution can be found to align multiple beams and make them operate with reduced down time, this may still not be enough in practice because so many beams cannot be made to simultaneously operate in a particular part for many reasons including heat dissipation, laser attenuation by the vaporized gas cloud produced by too many lasers and cost. A solution that can deliver a thousand-time factor in the manufacturing performance at an affordable cost is needed to allow supercapacitors made using materials such as graphene to be economically made with lasers.

SUMMARY OF THE INVENTION

Technical Problem

Laser beams have been used extensively in manufacturing processes for many decades now. There are many options among wavelengths, power levels, pulse width, focusing and positioning devices to choose from. This great variety of choices for equipment and configuration suits the needs for most applications and produces very good results and is the main reason why lasers have been so successfully integrated into manufacturing processes in many different areas such as cutting, cleaning, engraving, welding, measuring, and many others.

There are many variations of equipment, configurations and materials but in most applications the common aspect is that a laser beam is produced, collimated, focused, pointed to a target and stopped once it has achieved the intended goal. In some cases, the laser beam is pulsated over convenient periods of time that can be very short to produce the intended result. But in almost all cases what strikes the target is a single beam or a beam composed of a relatively small number of rays that have been produced using optic devices to split the original beam in a very specific and fixed way given by the optic device design.

An important part of typical laser manufacturing equipment is a control system that can deflect the laser beam using mirrors or prisms and position the beam accurately where it is intended to reach and at the same time be able to move the mirror or prism so that the beam can move at relatively high speeds without losing accuracy to improve production speed.

Despite all this flexibility, existing laser systems face difficulties when used to manufacture smaller size parts with a very high number of tiny and intricate details such as a graphene supercapacitor. Laser beams have been proposed to construct a graphene supercapacitor either by cutting the supercapacitor fringes out of a piece of material containing graphene or by drawing the fringes into a block of graphene oxide. In the latter case, the laser heats the material causing the reduction of the graphene oxide, a substance that does not conduct electricity, into graphene, a substance that is a good conductor of electricity.

The reduction of graphene oxide is simpler to implement but has a big disadvantage because this approach produces a two-dimensional 2D supercapacitor. As the graphene oxide remains in the structure only the top portions of the material where the graphene oxide was reduced in the areas that were hit by the laser form the graphene tracks that are accessible to the electrolyte. As the energy storage capability of a supercapacitor is proportional to the active area of the graphene that is in contact with the electrolyte, then this approach cannot compete with another method that produces a three-dimensional 3D graphene structure where all the exposed graphene layers have access to the electrolyte.

Such a structure could in principle be created by cutting a thick slab of graphene into many thin fringes leaving channels between any two adjacent fringes that are then filled with the electrolyte. That is the goal of a graphene supercapacitor manufacturer in order to produce a 3D graphene lattice with very high aspect ratio and higher energy storage capability than a 2D supercapacitor.

The challenge however to cut a thick slab of graphene into many tiny fringes is significant. To achieve best results, the fringes must be as thin as possible, orders of magnitude smaller than the other dimensions of the device. This means a mechanical cutting tool cannot be used. A particle beam ion or electron beam, or a laser beam are the only possibilities. Laser beams have been better developed for manufacture and are more easily procured and are therefore less expensive and tend to be more effective than electron or ion beams. Lasers appear to be the best choice in this situation, but the challenge remains exceedingly difficult.

The focus is a big challenge. Producing a very narrow laser beam requires very precise collimation and focus and the required optics impose a very short focal distance that is incompatible with trying to cut a structure with very high aspect ratio. The focusing problem imposes restrictions on the aspect ratio, limiting the maximum thickness of material that can be cut with respect to the beam diameter using traditional laser systems.

The target for a good supercapacitor though remains the same, obtaining a high aspect ratio or much higher thickness than the beam width. Supposing the focus problem could somehow be solved, for the purpose of understanding the other implications of using high aspect ratio, the calculations for a hypothetical example follow in the next paragraphs.

Assuming the graphene slab being cut has dimensions of 10 cm long by 5 cm wide and 1 cm thick, about the size typical of a handheld device battery, and the dimensions of a single fringe are in the range of one micron, the fringes will be four orders of magnitude smaller than the other dimensions and the aspect ratio, the fringe width to slab thickness, will be 1:10000, very high indeed.

Assuming a 1 μm thin laser beam could be produced, positioned and focused with very high accuracy to cut the channels separating the fringes, this would require 24999×10 cm long cuts to make all the 25000 fringes in the 5 cm width. Assuming a laser maximum velocity of 1 m/s, that will require 2499 seconds or approximately 42 minutes for a single pass.

The problem is compounded because at 1 m/s the laser beam cannot cut very deep into the material as that would require a high level of power that in turn would damage the delicate structure being created. Using high power causes too much heat to enter the structure at a single point causing the surrounding areas to heat up to near the melting point and become weakened. Additionally, too much power produces too much vaporized material in the illuminated laser spot that does not have time to escape the structure producing a pressure wave that warps the fragile partially melted material in the vicinity. Furthermore, the produced vaporized material absorbs part of the incident power reducing the effective power and therefore the ability to remove additional material.

As a result, at 1 m/s at a reasonable level of power, the laser beam will be able to cut just a thin layer of the material generating the need for multiple passes to complete the structure. Assuming a value of 10 μm cut at each pass, a value that is achievable considering practical focusing limitations, to cut all the way down to 1 cm, 1000 passes will be required and the time needed to complete the structure working 24/7 will be in the order of 29 days.

Even assuming very optimistic and improbable improvements, multiplying the laser speed by a factor of 10 and the amount of material removed at each pass by another factor of 10 and even using multiple laser beams simultaneously disregarding the very demanding alignment and synchronization challenges among all beams and the focusing limitations, the manufacturing time would still be too high and by any measure impractical for mass production. Even more so if considered that the calculations in the above paragraphs were made for a single supercapacitor with dimensions compatible with a handheld device. The challenge to mass produce devices to be used not only in handheld devices but also with electric cars, photovoltaic arrays, wind turbines and other applications that require much larger electricity storage capacities, hence require larger device sizes, is even more daunting. A better solution is needed.

Technical Solution

An object and advantage of the invention is a filtering device composed of one or more filtering patterns that serves as a template to produce a specific part by a process of laser cutting.

Another object and advantage of the invention is to use several different filtering devices each one with a specific design to produce entire parts or specific regions of a part by a process of laser cutting.

Another object and advantage of the invention is a filtering device composed of one or more filtering patterns that serves a similar function as a beam splitter and collimator for the laser beam.

Another object and advantage of the invention is the use of a filtering device composed of one or more filtering patterns with the first filtering pattern placed at an angle to the laser beam so that the reflected laser beam is not reflected back to the laser source.

Another object and advantage of the invention is a manufacturing method of using a filtering device composed of one or more filtering patterns to split one or multiple laser beams into a plurality of collimated child laser beams following the pattern contained in the filtering patterns and use the child laser beams to do the intended job of cutting the material increasing the accuracy and speed of the process.

Another object and advantage of the invention is an advanced double layer graphene supercapacitor manufactured using the proposed method of using a filtering device composed of one or more filtering patterns to split one or multiple laser beams into a plurality of collimated child laser beams following the pattern contained in the filtering patterns and use the child laser beams to do the intended job increasing the accuracy and speed of the process.

Accordingly, the present invention is related to a filtering pattern for the collimation of a laser beam, comprising a glass layer; a sealant layer comprising a pattern; wherein the sealant layer is formed on a surface of the glass layer and the sealant layer is designed to absorb the laser beam; wherein the pattern in the sealant layer is formed by a plurality of gaps, the gaps designed to allow the laser beam to pass through the sealant layer and produce cuts on a substrate; and the pattern formed by the plurality of gaps is on a 1 to 1 scale to the cuts on the substrate.

Furthermore, the present invention is related to a filtering device for the collimation of a laser beam comprising a plurality of filtering patterns each filtering pattern comprising a pattern formed by a plurality of gaps, the gaps designed to allow the laser beam to pass through the sealant layer and produce cuts on the substrate; wherein the plurality of filtering patterns are placed at variable distances to each other in perfect alignment so that when seen from the point of view of the incident laser beam all filtering patterns are seen as a single filtering pattern and correspondent gaps in the filtering patterns are seen as a single gap; wherein the filtering device is configured to reflect or absorb portions of a laser beam that enter the plurality of filtering patterns at a diversion angle non-perpendicular to the plurality of filtering patterns and at an angle greater than the angle allowed by the edges of correspondent gaps in the first and last filtering pattern and smaller than the maximum diversion angle of the laser source.

Furthermore, the present invention is related to a method for the production of a supercapacitor using a filtering device and laser, comprising forming a plurality of filtering patterns with gaps in the intended pattern to be created; aligning a plurality of filtering patterns with a laser source; aligning a substrate to the plurality of filtering patterns; emitting a laser beam from the laser source; reflecting or absorbing portions of the laser beam that encounter a reflective or absorptive structure in any of the plurality of filtering patterns; cutting the substrate with the portion of the laser beam entering the gaps to produce the pattern contained in the filtering patterns, resulting in a structure with a first terminal and a second terminal of a supercapacitor.

Advantageous Effects of the Invention

The proposed invention uses a simple yet effective filtering device that works as a laser beam splitter producing several thousand child laser beams from a single parent laser beam. The filtering device is constructed with the same shape of the part being produced and allows for multiple laser beams to work on different areas of the same part simultaneously further improving the manufacturing time. The proposed filtering device also works as a collimator, reducing the laser dispersion angle without the need of complicated optics.

The proposed filtering device works as a template for the part being produced. The filtering device is kept in the same position relative to the part at all times eliminating the need for precise control of the parent laser beam used. Even if the laser beam moves with jitter, if it is shut off and turned on again or if it works with poor synchronicity and poor alignment with other laser beams in the manufacture of a particular part, the filtering device filters all imprecision out of the process and allows only precise child laser beams to pass and make quick clean cuts in the part.

The proposed invention has the advantage of allowing a very quick and precise manufacture of the intended parts in a time frame several thousand times shorter than using existing processes and that could not be attainable in any other way.

The proposed invention has the advantage to be very simple and cheap, dramatically reducing manufacturing costs. Because of the simplicity and low cost, different filtering devices can be easily and quickly constructed to manufacture supercapacitors to a very wide range of dimensions and specifications to match the needs for different applications.

DETAILED DESCRIPTION OF EMBODIMENTS

The present invention is composed of an apparatus designed to achieve the goal of making a very high number of very thin cuts into a thick layer of material. This apparatus can be used for many applications and in particular to create a functional double layer, three-dimensional supercapacitor.

The material can be made of graphene and a binder; a mixture of graphene, carbon nanotubes, fullerenes and activated carbon and a binder; a block of graphite, or of another conductive or other type material. The binder can be a resin, plastic, glue or another substance that serves as a base or solvent for all the components so they can be properly mixed and then after an adequate treatment settle into a solid. The material can also be pressed into a solid using a hydraulic press or smelted and cast into a mold and machined into the final intended shape. The laser cutting apparatus can be used in a wide variety of materials and the reference to graphene and other components such as carbon nanotube, activated carbon, fullerenes and graphite is made only because those are the best suited materials to produce a high energy density double layer supercapacitor that is an object of this invention.

For consistence and to avoid unnecessary redundancy, the piece of material being cut regardless of its composition is henceforward called graphene layer. That does not infer that only graphene is used or that other materials such as graphite or even metals cannot be cut using the proposed invention. The invention is therefore not limited to any specific material.

While references may be made to upper, lower, vertical and horizontal, these terms are used merely to describe relationships and not to limit the operation or use of the present invention to any one orientation.

First Embodiment

FIG.1shows a substrate30where a series of perforations31are made at both ends of the substrate. The substrate30can be made using a very thin plastic film, a thin sheet of glass or a thin sheet of a suitable insulting material. A graphene layer32is then applied on top of the substrate30in such a way to cover the surface and to flow through to cover surfaces through all the perforations31. To ensure that the graphene layer32has a good bond to the substrate30, a surface treatment such as surface plasma eroding process can be applied to the substrate30if necessary.

FIG.2shows the substrate30and the graphene layer32from a side angle to better illustrate the differences in thickness between the substrate that is made as thin as possible and the graphene layer32that is made as thick as possible with the limitation on thickness being dependent on the graphene layer32being suitable to cut through its entire thickness by the process. Beneath the substrate30a pair of under contacts33is created out of the same material that is used to create the graphene layer32. The perforations31create a series of bridges that are filled with the same material as the graphene layer32and the under contacts33in such a way that the graphene layer32and the under contacts33remain physically and electrically connected across the substrate30.

FIG.3shows an isometric view of the graphene layer32applied over the substrate30also showing the perforations31and the under contacts33in dashed lines to better illustrate the produced part that will be cut using the apparatus of this invention. The X-axis along the length and the Y-axis along the width of the graphene layer are indicated by the arrows. These directions are indicated in the same way in other drawings and will be used later on as reference and to explain the operation.

FIG.4shows an embodiment of a filtering pattern34that is composed of a glass layer37with portions of the glass layer37coated with a mirror layer38along the underside of the glass layer37with the mirror layer38formed in a pattern.

The glass layer37works as support and protection from oxidation to the mirror layer38. The mirror layer38is created with a thin layer of a highly reflective material in the laser bandwidth used and with the same template in a 1:1 scale as the structure that is intended to be created in the graphene layer. The mirror layer38in some embodiments is coated at the underside, opposite to the glass layer37, with a dark sealant layer39in the same shape as the mirror layer38to protect the mirror layer38from oxidation and to absorb any laser light hitting the underside of the mirror layer38.

As the embodiment of the filtering pattern34shown inFIG.4is used to create a graphene supercapacitor the mirror layer38is constructed in the shape of two intertwined structures each one composed of a terminal40a,40band a set of parallel fringes41a,41bin such a way that the two terminals40a,40bare each connected to its own set of fringes41a,41brespectively but not to any of the fringes belonging to the set of the other terminal. In other words, there is no connection between the two terminals40a,40bthat remain physically separated from each other. The mirror layer38and sealant layer39patterns may be formed through a photoresist process that can achieve a consistent resolution of fifty nanometers in order to produce electrodes that are sufficiently precise and uniform to achieve supercapacitors having high energy densities as described in U.S. Pat. No. 10,373,765 to the same inventor or by etching or other processes.

DetailFIG.4Ashows a small part of the filtering pattern34in greater magnification to show the placement of the glass layer37, the mirror layer38and the sealant layer39in better detail. The sealant layer39, shown in thick hatched lines, has the same shape as the mirror layer38and the sealant layer39is placed directly under the mirror layer38to prevent oxidation and consequent degradation of the mirror layer38.

FIG.5shows an embodiment of a filtering device45made with one or more, three in the embodiment shown inFIG.5, filtering patterns34a,34b,34c. The filtering patterns34a,34b,34care all identical, composed of the glass layer37a,37b,37ccoated with the mirror layer38a,38b,38con the underside. The filtering patterns34a,34b,34care placed at variable distances to each other with all filtering patterns34a,34b,34cplaced in perfect alignment to each other so that when seen from above the mirror layers38a,38b,38care all in perfect alignment. A section plane perpendicular to the filtering patterns34a,34b,34cat a point where the mirror layers38a,38b,38ccontain only parallel fringes41ais indicated by the section line A-A.

FIG.5Ashows a cross-section of the filtering device45shown inFIG.5along the A-A section line. The filtering patterns34a,34b,34care sectioned by a plane perpendicular to the respective glass layers37a,37b,37cand the mirror layers38a,38b,38c. The sealant layers39a,39b,39care seen directly below the mirror layers38a,38b,38c.

The filtering patterns34a,34b,34care placed at variable distances apart from each other in perfect alignment so that when seen from above all fringes41a,41b,41cas well as the other structures of the mirror layers38a,38b,38cand the sealant layers39a,39b,39care all in perfect alignment.

A series of incoming rays48athrough48jand for the incoming rays that are reflected a series of corresponding reflected rays49dthrough49jare shown to illustrate the geometry and workings of the filtering device45.

To facilitate the identification of individual fringes a grid structure with letters and numbers has been created. This way to refer to the fringe41a, the reference A11can be used. Likewise, the fringe41bcan be appointed by the reference B15and the fringe41c, by the reference C8. Using this grid structure it is easy to note that the fringes A1, B1, and C1are in perfect alignment and likewise any fringes with different letters but with the same number are aligned.

Any set of fringes with different letters but with the same number that are aligned create a channel that allows incoming rays to pass through. Any incoming ray hitting a fringe at any level is reflected.

The incoming ray48agoes through all filtering patterns34a,34b,34cas it is perpendicular to the filtering patterns and does not intercept any fringe, passing just to the right of the fringes located at position1. Likewise the incoming ray48balso goes through all filtering patterns34a,34b,34cas it is perpendicular to the filtering patterns and does not intercept any fringe, passing just to the left of the fringes located at position2. The incoming ray48aand the incoming ray48bpass at the edges of the channel1-2, between the fringes located at the positions1and2.

The incoming ray48cgoes through all filtering patterns34a,34b,34cat the maximum possible diversion angle with the normal to the filtering patterns allowed for a ray going through a given channel, passing just at the right of the fringe located at A2and to the left of the fringe located at C3. The diversion angle can be ascertained using the dashed line drawn perpendicular to the filtering patterns at the point where the incoming ray48cpasses the fringe located at A2.

The incoming ray48dgoes through the filtering pattern34a, passing just at the left of the fringe located at A3. The incoming ray48dhas a smaller diversion angle than the maximum diversion angle of the incoming ray48c, but because it passes just at the left edge of the channel2-3it does not go all the way through. Instead it hits the fringe located at B3and is reflected. The reflected ray49dgoes back and is absorbed by the sealant layer at the back of the fringe located at A3.

The incoming ray48egoes through the filtering pattern34a, passing just at the left of the fringe located at A4. The incoming ray48ehas a larger diversion angle than the diversion angle of the incoming ray48dso it hits the fringe located at B4further to the right than the incoming ray48dhits the fringe located at B3. As a result the reflected ray49emisses the sealant layer at the back of the fringe located at A4and continues back towards the laser source as any other incoming ray hitting a fringe of the filtering pattern34a.

The incoming ray48fgoes through the filtering pattern34a, passing just at the left of the fringe located at A6. The incoming ray48fhas a larger diversion angle than the diversion angle of the incoming ray48ejust sufficient for it to go through the filtering pattern34bmissing the fringe located at B6continuing until it hits the fringe located at C7. The reflected ray49fgoes back, misses the fringes located at B7and B8and is absorbed by the sealant layer at the back of the fringe located at A8.

The incoming ray48ggoes through the filtering pattern34a, passing just at the left of the fringe located at A9. The incoming ray48ghas a larger diversion angle than the diversion angle of the incoming ray48fthe maximum possible for it to go through the filtering pattern34bbut not go through the filtering pattern34chitting the fringe located at C10. The reflected ray49ggoes back and is absorbed by the sealant layer at the back of the fringe located at B11.

The incoming ray48hgoes through the filtering pattern34a, passing just at the left of the fringe located at A12. The incoming ray48hhas a larger diversion angle than the diversion angle of the incoming ray48gexceeding the maximum possible diversion angle that still hits any fringe. As a result, the incoming ray48hgoes through all filtering patterns34a,34b,34cexiting the filtering device45just at the right of the fringe located at C13.

The incoming ray48igoes through the filtering pattern34a, passing just at the left of the fringe located at A13. The incoming ray48ihas a larger diversion angle than the incoming ray48hand at the same time still misses all fringes. As a result the incoming ray48igoes through all filtering patterns34a,34b,34cexiting the filtering device45just at the left of the fringe located at C15.

The incoming ray48jgoes through the filtering pattern34a, passing just at the left of the fringe located at A14. The incoming ray48jhas a larger diversion angle than the diversion angle of the incoming ray48icausing it to hit the fringe located at B15. The reflected ray49jgoes back and is absorbed by the sealant layer at the back of the fringe located at A16.

The embodiment of the filtering device45with three filtering patterns34a,34b,34cas shown inFIG.5andFIG.5Aallows unwanted incoming rays with diversion angles equal or greater than the diversion angle of the incoming ray48hto potentially go through. In fact a series of diversion angle ranges are allowed through the first diversion angle range between the diversion angle of the incoming ray48hand the diversion angle of the incoming ray48i. The laser source used must have sufficient collimation to produce laser beams with smaller diversion angles than the diversion angle of incoming ray48h. If sufficient collimation is not attainable, additional filtering patterns can be used to guarantee that all laser beams produced hitting the filtering device45at an unwanted angle are stopped.

FIG.5Bshows a cross-section of an alternative embodiment of the filtering device45shown inFIG.5along the A-A section line. The filtering patterns34a,34b,34care sectioned by a plane perpendicular to the respective glass layers37a,37b,37cbut differently from the embodiment show inFIG.5A, the mirror layers are not applied and instead only the sealant layers39a,39b,39cthat absorb the laser light are present.

The filtering patterns34a,34b,34care assembled at variable distances to each other but every filtering pattern34a,34b,34cis placed in perfect alignment to each other so that when seen from above all fringes41a,41b,41cas well as the other structures of the sealant layers39a,39b,39care all in perfect alignment.

A series of incoming rays48athrough48jare shown to illustrate the geometry and workings of the filtering device45.

As noted above, to facilitate the identification of individual fringes a grid structure with letters and numbers has been created. This way to refer to the fringe41a, the reference A11can be used. Likewise, the fringe41bcan be appointed by the reference B15and the fringe41c, by the reference C8. Using this grid structure it is easy to note that the fringes A1, B1, and C1are in perfect alignment and likewise any fringes with different letters but with the same number are aligned.

Any set of fringes with different letters but with the same number that are aligned create a channel that allows incoming rays to pass through. Any incoming ray hitting a fringe at any level is absorbed.

The incoming ray48agoes through all filtering patterns34a,34b,34cas it is perpendicular to the filtering patterns and does not intercept any fringe, passing just to the right of the fringes located at position1. Likewise the incoming ray48balso goes through all filtering patterns34a,34b,34cas it is perpendicular to the filtering patterns and does not intercept any fringe, passing just to the left of the fringes located at position2. The incoming ray48aand the incoming ray48bpass at the edges of the channel1-2, between the fringes located at the positions1and2.

The incoming ray48cgoes through all filtering patterns34a,34b,34cat the maximum possible diversion angle with the normal to the filtering patterns allowed for a ray going through a given channel, passing just at the right of the fringe located at A2and to the left of the fringe located at C3. The diversion angle can be ascertained using the dashed line drawn perpendicular to the filtering patterns at the point where the incoming ray48cpasses the fringe located at A2.

The incoming ray48dgoes through the filtering pattern34a, passing just at the left of the fringe located at A3. The incoming ray48dhas a smaller diversion angle than the maximum diversion angle of the incoming ray48c, but because it passes just at the left edge of the channel2-3it does not go all the way through. Instead it hits the fringe located at B3and is absorbed.

The incoming ray48egoes through the filtering pattern34a, passing just at the left of the fringe located at A4. The incoming ray48ehas a larger diversion angle than the diversion angle of the incoming ray48dso it hits the fringe located at B4further to the right than the incoming ray48dhits the fringe located at B3and is also absorbed.

The incoming ray48fgoes through the filtering pattern34a, passing just at the left of the fringe located at A6. The incoming ray48fhas a larger diversion angle than the diversion angle of the incoming ray48ejust sufficient for it to go through the filtering pattern34bmissing the fringe located at B6continuing until it hits the fringe located at C7where it is absorbed.

The incoming ray48ggoes through the filtering pattern34a, passing just at the left of the fringe located at A9. The incoming ray48ghas a larger diversion angle than the diversion angle of the incoming ray48fthe maximum possible for it to go through the filtering pattern34bbut not go through the filtering pattern34chitting the fringe located at C10where it is absorbed.

The incoming ray48hgoes through the filtering pattern34a, passing just at the left of the fringe located at A12. The incoming ray48hhas a larger diversion angle than the diversion angle of the incoming ray48gexceeding the maximum possible diversion angle that still hits any fringe. As a result, the incoming ray48hgoes through all filtering patterns34a,34b,34cexiting the filtering device45just at the right of the fringe located at C13.

The incoming ray48igoes through the filtering pattern34a, passing just at the left of the fringe located at A13. The incoming ray48ihas a larger diversion angle than the incoming ray48hand at the same time still misses all fringes. As a result the incoming ray48igoes through all filtering patterns34a,34b,34cexiting the filtering device45just at the left of the fringe located at C15.

The incoming ray48jgoes through the filtering pattern34a, passing just at the left of the fringe located at A14. The incoming ray48jhas a larger diversion angle than the diversion angle of the incoming ray48icausing it to hit the fringe located at B15where it is absorbed.

The embodiment of the filtering device45with three filtering patterns34a,34b,34cas shown inFIG.5andFIG.5Ballows incoming rays with diversion angle equal or greater than the diversion angle of the incoming ray48hto potentially go through. In fact a series of diversion angle ranges are allowed through, the first diversion angle range between the diversion angle of the incoming ray48hand the diversion angle of the incoming ray48i. The laser source used must have sufficient collimation to produce laser beams with smaller diversion angles than the diversion angle of incoming ray48h. If sufficient collimation is not attainable, additional filtering patterns can be used to guarantee that all laser beams produced hitting the filtering device45at an unwanted angle are stopped and absorbed by the sealant layers39a,39b,39c.

Because in the embodiment shown inFIG.5Bthe laser beams are absorbed by the fringes of the sealant layers39a,39b,39c, depending on the power of the laser source used, some cooling method to prevent damage to the sealant layers39a,39b,39cis required. This can be done easily for example by blowing cool air between the filtering patterns34a,34b,34c.

FIG.6shows an embodiment of a filtering device with tilted filtering pattern with respect to the X-axis46made with one filtering pattern tilted with respect to the X-axis35aand one or more, two in the embodiment shown inFIG.6, filtering patterns34b,34c. The filtering pattern tilted with respect to the X-axis35ais composed of a modified glass layer42aand a modified mirror layer43a.

The filtering patterns34b,34care identical, composed of the glass layer37b,37ccoated with the mirror layer38b,38cin the underside. The filtering patterns34b,34care assembled at a variable distance to each other with every filtering pattern34b,34cbeing placed in perfect alignment to each other so that when seen from above the mirror layers38b,38care all in perfect alignment.

Because the filtering pattern tilted with respect to the X-axis35ais installed at a certain inclination angle, the modified glass layer42aand the modified mirror layer43aneed to be distorted along the X-axis to compensate for the inclination angle of installation. This distortion extends all the structures along the X-axis by a trigonometric factor given by the inverse of the cosine of the inclination angle the secant of the inclination angle. This distortion causes the total length of the modified glass layer42aand the modified mirror layer43ato increase and the position of every feature to move by the exact factor needed to compensate for the installation at the chosen inclination angle. This way, when seen from above, the modified glass layer42aperfectly matches the glass layers37b,37cand the modified mirror layer43aperfectly matches the mirror layers38b,38ccausing the filtering pattern tilted with respect to the X-axis35ato be seen from above exactly as a filtering pattern34b,34c. Another way to explain this is that the projection of the filtering pattern tilted with respect to the X-axis35aalong a line normal to the filtering patterns34b,34chas exactly the same shape and perfectly matches the filtering patterns34b,34c.

The filtering pattern tilted with respect to the X-axis35aand the filtering patterns34b,34care assembled at variable distances to each other and the distance between the filtering pattern tilted with respect to the X-axis35aand the filtering pattern34bvaries along the X-axis because of the angle that the filtering pattern tilted with respect to the X-axis35ais placed at, the distance being shorter to the left and longer to the right as shown inFIG.6.

FIG.6Ashows a cross-sectional view of the filtering device with tilted filtering pattern with respect to the X-axis46shown inFIG.6along the A-A section line. The filtering pattern tilted with respect to the X-axis35aand the filtering patterns34b,34care sectioned by a plane perpendicular to the glass layers37b,37c. The section plane intercepts the modified glass layer42a, the modified mirror layer43aand the mirror layers38b,38c. The modified sealant layer44aand the sealant layers39b,39care seen directly below the modified mirror layer43aand the mirror layers38b,38crespectively.

All elements are placed in perfect alignment to each other so that when seen from above all fringes41a,41b,41cas well as the other structures of the modified mirror layer43a, the mirror layers38b,38c, the modified sealant layer44aand the sealant layers39b,39care all in perfect alignment.

The filtering pattern tilted with respect to the X-axis35aand the filtering patterns34b,34care assembled at variable distances to each other and the distance between the filtering pattern tilted with respect to the X-axis35aand the filtering pattern34bvaries along the X-axis because of the angle that the filtering pattern tilted with respect to the X-axis35ais placed at.

In taking a cross-section A-A at a particular point along the length, the distance between the filtering pattern tilted with respect to the X-axis35aand the filtering pattern34bis constant when viewed through the A-A section line that extends through the width, as shown inFIG.6. The distance between the filtering pattern tilted with respect to the X-axis35aand the filtering pattern34bchanges depending upon which point along the length, the A-A section line is taken which is different than the constant distance between the filtering pattern34aand the filtering pattern34binFIG.5A.

If the A-A section line is made further to the right along the length inFIG.6, the distance between the filtering pattern tilted with respect to the X-axis35aand the filtering patterns34binFIG.6Ais longer than the actual distance seen inFIG.6A. On the other hand, if the A-A section line is made further to the left inFIG.6, the distance between the filtering pattern tilted with respect to the X-axis35aand the filtering patterns34binFIG.6Ais shorter than the actual distance seen inFIG.6A. If the A-A section line is made even further to the left, the distance between the filtering pattern tilted with respect to the X-axis35aand the filtering patterns34binFIG.6Ais reduced further and could be shorter than the distance between the filtering pattern34aand the filtering pattern34binFIG.5A.

A series of incoming rays48athrough48jand for the incoming rays that are reflected a series of corresponding reflected rays49dthrough49jare shown to illustrate the geometry and workings of the filtering device with tilted filtering pattern with respect to the X-axis46.

As noted above, to facilitate the identification of individual fringes a grid structure with letters and numbers has been created. This way to refer to the fringe41a, the reference A7can be used. Likewise, the fringe41bcan be appointed by the reference B15and the fringe41c, by the reference C8. Using this grid structure it is easy to note that the fringes A1, B1, and C1are in perfect alignment and likewise any fringes with different letters but with the same number are aligned.

Any set of fringes with different letters but with the same number that are aligned creates a channel that allows incoming rays to pass through. Any incoming ray hitting a fringe at any level is reflected.

The changing distance between the filtering pattern tilted with respect to the X-axis35aand the filtering patterns34balong the X-axis as explained above impacts the performance of the filtering device with tilted filtering pattern with respect to the X-axis46seen inFIG.6andFIG.6Athat does not have the same performance as the filtering device shown inFIG.5andFIG.5Abut provides the improvement of reducing damage to the laser from a reflected ray.

To facilitate the visualization and understanding of this performance change that translates into variations in maximum allowed diversion angles, similar incoming rays are drawn and numbered the same way inFIG.5AandFIG.6Aso that the differences in incidence angles, when applicable, are easy to ascertain.

The incoming ray48agoes through the filtering pattern tilted with respect to the X-axis35aand other filtering patterns34b,34cas it is perpendicular to the filtering patterns and does not intercept any fringe, passing just to the right of the fringes located at position1. Likewise the incoming ray48balso goes through the filtering pattern tilted with respect to the X-axis35aand all filtering patterns34b,34cas it is perpendicular to the filtering patterns and does not intercept any fringe, passing just to the left of the fringes located at position2. The incoming ray48aand the incoming ray48bpass at the edges of the channel1-2, between the fringes located at the positions1and2.

The incoming ray48cgoes through the filtering pattern tilted with respect to the X-axis35aand other filtering patterns34b,34cat the maximum possible diversion angle with the normal to the filtering patterns allowed for a ray going through a given channel, passing just at the right of the fringe located at A2and to the left of the fringe located at C3. The diversion angle can be ascertained using the dashed line drawn perpendicular to the filtering patterns at the point where the incoming ray48cpasses the fringe located at A2.

The diversion angle of the incoming ray48cseen inFIG.6Ais smaller than the diversion angle of the incoming ray48cseen onFIG.5A. This is because at the point of the section the filtering pattern tilted with respect to the X-axis35ais further apart from the filtering pattern34cinFIG.6Athan the distance of the filtering pattern34afrom the filtering pattern34cinFIG.5Aand the longer distance forces a reduction on the allowed maximum angle. It is shown inFIG.6Athat, as the distance between the filtering pattern tilted with respect to the X-axis35aand the filtering patterns34band34cvaries along the X-axis, so does the diversion angle allowed. This effect affects all other incoming rays on a similar manner and to facilitate the comparison betweenFIG.5AandFIG.6Asimilar incoming rays have been numbered the same way.

The incoming ray48dgoes through the filtering pattern tilted with respect to the X-axis35apassing just at the left of the fringe located at A3. The incoming ray48dhits the fringe located at B3and is reflected. The reflected ray49dgoes back and is absorbed by the sealant layer at the back of the fringe located at A3.

The incoming ray48egoes through the filtering pattern tilted with respect to the X-axis35apassing just at the left of the fringe located at A4. The incoming ray48ehas a larger diversion angle than the diversion angle of the incoming ray48dso it hits the fringe located at B4further to the right than the incoming ray48dhits the fringe located at B3. As a result the reflected ray49emisses the sealant layer at the back of the fringe located at A4and continues back towards the laser source as any other incoming ray hitting a fringe of the filtering pattern tilted with respect to the X-axis35a.

Compared to the incoming ray48einFIG.5A, the incoming ray48einFIG.6Ahas a smaller diversion angle and yet passes further to the right of the fringe located at A4because of the difference in the geometry, particularly the longer distance between the filtering pattern tilted with respect to the X-axis35aand the filtering patterns34bat the point the section was made.

The incoming ray48fgoes through the filtering pattern tilted with respect to the X-axis35apassing just at the left of the fringe located at A6. The incoming ray48fhas a larger diversion angle than the diversion angle of the incoming ray48ejust sufficient for it to go through all the filtering patterns34band34cexiting the filtering device with tilted filtering pattern with respect to the X-axis46just at the left of the fringe located at C7. Compared to the incoming ray48finFIG.5Athat is reflected and absorbed, the incoming ray48einFIG.6Ahas a completely different behavior.

The diversion angle of the incoming ray48finFIG.6Ais smaller than the diversion angle of the incoming ray48finFIG.5Abecause this angle is given by the distance between the left side of fringe A6and the right side of fringe B6. As the distance between the filtering pattern tilted with respect to the X-axis35aand the filtering pattern34bis longer inFIG.6Athan the distance between the filtering pattern34aand the filtering pattern34binFIG.5A, this allows for the incoming ray48fwith smaller diversion angle inFIG.6Ato find a gap and go through all the filtering patterns missing all the fringes.

As the distance between the filtering pattern tilted with respect to the X-axis35aand the filtering pattern34bvaries along the X-axis, taking a cross-section A-A along different points provides the variation in the distance between the filtering pattern tilted with respect to the X-axis35aand the filtering pattern34b.As a result, the diversion angle that is allowed through varies. At the points in the X-axis where the distance between the filtering pattern tilted with respect to the X-axis35aand the filtering pattern34bare equal or smaller than the distance between the filtering pattern34aand the filtering pattern34bonFIG.5Athe gap is closed and the incoming ray48fis reflected as inFIG.5A.

The incoming ray48ggoes through the filtering pattern tilted with respect to the X-axis35a, passing just at the left of the fringe located at A9. The incoming ray48ghas a larger diversion angle than the diversion angle of the incoming ray48fbut instead of passing through as the incoming ray48f, the incoming ray48ghits the fringe located at C10. The reflected ray49ggoes back and misses the sealant layer at the back of the fringes located at B11and A11and continues back towards the laser source as any other incoming ray hitting a fringe of the filtering pattern tilted with respect to the X-axis35a.

The incoming ray48hgoes through the filtering pattern tilted with respect to the X-axis35a, passing just at the left of the fringe located at A12. The incoming ray48hhas a larger diversion angle than the diversion angle of the incoming ray48gand goes through all filtering patterns34b,34cexiting the filtering device with tilted filtering pattern with respect to the X-axis46just at the right of the fringe located at C13. The diversion angle of the incoming ray48hinFIG.6Ais smaller than the diversion angle of the incoming ray48hinFIG.5Abecause this angle is given by the distance between the left side of fringe A12and the right side of fringe C13.

The incoming ray48igoes through the filtering pattern tilted with respect to the X-axis35a, passing just at the left of the fringe located at A13. The incoming ray48ihas a larger diversion angle than the incoming ray48hand also goes through all filtering patterns34b,34cexiting the filtering device with tilted filtering pattern with respect to the X-axis46between the fringes located at C14and C15. The diversion angle of the incoming ray48iinFIG.6Ais smaller than the diversion angle of the incoming ray48iinFIG.5Abecause this angle is given by the distance between the left side of fringe A13and the left side of fringe B14.

The incoming ray48jgoes through the filtering pattern tilted with respect to the X-axis35a, passing just at the left of the fringe located at A14. The incoming ray48jhas a larger diversion angle than the diversion angle of the incoming ray48icausing it to hit the fringe located at B15. The reflected ray49jgoes back and is absorbed by the sealant layer at the back of the fringe located at A16.

The embodiment of the filtering device with tilted filtering pattern with respect to the X-axis46with one filtering pattern tilted with respect to the X-axis35aand two filtering patterns34b,34cas shown inFIG.6andFIG.6Afeatures a position dependent behavior along the X-axis allowing unwanted incoming rays with various diversion angles to potentially go through, depending on the point of incidence along the X-axis. As a result, the laser source used must have better collimation than the collimation required to operate using the apparatus shown inFIG.5andFIG.5A.

To improve the performance of the filtering device with tilted filtering pattern with respect to the X-axis46, additional filtering patterns parallel to the filtering patterns34b,34ccan be used to guarantee that all laser beams produced by the available laser source hitting the filtering device with tilted filtering pattern with respect to the X-axis46at an unwanted angle are stopped.

FIG.6Bshows a cross-section of an alternative embodiment of the filtering device with tilted filtering pattern with respect to the X-axis46shownFIG.6along the A-A section line. The filtering pattern tilted with respect to the X-axis35aand the filtering patterns34b,34care sectioned by a plane perpendicular to the glass layers37b,37c. The section plane intercepts the modified glass layer42aand the glass layers37b,37c, but differently from the embodiment show inFIG.6Athe modified mirror layer and the mirror layers are not applied and instead only the modified sealant layer44aand the sealant layers39b,39cthat absorb the laser light are present.

All elements are placed in perfect alignment to each other so that when seen from above all fringes41a,41b,41cas well as the other structures of the modified sealant layer44aand the sealant layers39b,39care all in perfect alignment.

The filtering pattern tilted with respect to the X-axis35aand the filtering patterns34b,34care assembled at variable distances to each other and the distance between the filtering pattern tilted with respect to the X-axis35aand the filtering pattern34bvaries along the X-axis because of the angle that the filtering pattern tilted with respect to the X-axis35ais placed at.

In taking a cross-section A-A at a particular point along the length, the distance between the filtering pattern tilted with respect to the X-axis35aand the filtering pattern34bis constant when viewed through the A-A section line that extends through the width, as shown inFIG.6. The distance between the filtering pattern tilted with respect to the X-axis35aand the filtering pattern34bchanges depending upon which point along the length, the cross-section A-A is taken which is different than the constant distance between the filtering patterns34aand the filtering patterns34binFIG.5B.

If the A-A section line is made further to the right inFIG.6, the distance between the filtering pattern tilted with respect to the X-axis35aand the filtering patterns34binFIG.6Bis longer than the actual distance seen inFIG.6B. On the other hand, if the A-A section line is made further to the left inFIG.6, the distance between the filtering pattern tilted with respect to the X-axis35aand the filtering patterns34binFIG.6Bis shorter than the actual distance seen inFIG.6B. If the A-A section line is made even further to the left, the distance between the filtering pattern tilted with respect to the X-axis35aand the filtering patterns34binFIG.6Bis reduced further and could be shorter than the distance between the filtering pattern34aand the filtering pattern34binFIG.5B.

A series of incoming rays48athrough48jare shown to illustrate the geometry and workings of the filtering device with tilted filtering pattern with respect to the X-axis46.

To facilitate the identification of individual fringes a grid structure with letters and numbers has been created. This way to refer to the fringe41a, the reference A7can be used. Likewise, the fringe41bcan be appointed by the reference B15and the fringe41c, by the reference C8. Using this grid structure it is easy to note that the fringes A1, B1, and C1are in perfect alignment and likewise any fringes with different letters but with the same number are aligned.

Any set of fringes with different letters but with the same number that are aligned creates a channel that allows incoming rays to pass through. Any incoming ray hitting a fringe at any level is absorbed.

The changing distance between the filtering pattern tilted with respect to the X-axis35aand the filtering patterns34balong the X-axis as explained above impacts the performance of the filtering device with tilted filtering pattern with respect to the X-axis46seen inFIG.6andFIG.6Bthat does not have the same performance as the filtering device shown inFIG.5andFIG.5B.

To facilitate the visualization and understanding of this performance change that translates into variations in maximum allowed diversion angles, similar incoming rays are drawn and numbered the same way inFIG.5BandFIG.6Bso that the differences in incidence angles, when applicable, are easy to ascertain.

The incoming ray48agoes through the filtering pattern tilted with respect to the X-axis35aand other filtering patterns34b,34cas it is perpendicular to the filtering patterns and does not intercept any fringe, passing just to the right of the fringes located at position1. Likewise the incoming ray48balso goes through the filtering pattern tilted with respect to the X-axis35aand other filtering patterns34b,34cas it is perpendicular to the filtering patterns and does not intercept any fringe, passing just to the left of the fringes located at position2. The incoming ray48aand the incoming ray48bpass at the edges of the channel1-2, between the fringes located at the positions1and2.

The incoming ray48cgoes through the filtering pattern tilted with respect to the X-axis35aand other filtering patterns34b,34cat the maximum possible diversion angle with the normal to the filtering patterns allowed for a ray going through a given channel, passing just at the right of the fringe located at A2and to the left of the fringe located at C3. The diversion angle can be ascertained using the dashed line drawn perpendicular to the filtering patterns at the point where the incoming ray48cpasses the fringe located at A2.

The diversion angle of the incoming ray48cseen inFIG.6Bis smaller than the diversion angle of the incoming ray48cseen onFIG.5B. This is because the filtering pattern tilted with respect to the X-axis35ais further apart from the filtering pattern34cinFIG.6Bthan the distance of the filtering pattern34afrom the filtering pattern34cinFIG.5Band the longer distance forces a reduction on the allowed maximum angle. It is shown inFIG.6Bthat, as the distance between the filtering pattern tilted with respect to the X-axis35aand the filtering patterns34band34cvaries along the X-axis, so does the diversion angle allowed. This effect affects all other incoming rays on a similar manner and to facilitate the comparison betweenFIG.5BandFIG.6Bsimilar incoming rays have been numbered the same way.

The incoming ray48dgoes through the filtering pattern tilted with respect to the X-axis35apassing just at the left of the fringe located at A3. The incoming ray48dhits the fringe located at B3and is absorbed.

The incoming ray48egoes through the filtering pattern tilted with respect to the X-axis35apassing just at the left of the fringe located at A4. The incoming ray48ehas a larger diversion angle than the diversion angle of the incoming ray48dso it hits the fringe located at B4further to the right than the incoming ray48dhits the fringe located at B3.

Compared to the incoming ray48einFIG.5B, the incoming ray48einFIG.6Bhas a smaller diversion angle and yet hits the fringe located at B4at approximately the same point because of the difference in the geometry, particularly the longer distance between the filtering pattern tilted with respect to the X-axis35aand the filtering patterns34b.

The incoming ray48fgoes through the filtering pattern tilted with respect to the X-axis35apassing just at the left of the fringe located at A6. The incoming ray48fhas a larger diversion angle than the diversion angle of the incoming ray48ejust sufficient for it to go through all the filtering patterns34band34cexiting the filtering device with tilted filtering pattern with respect to the X-axis46just at the left of the fringe located at C7. Compared to the incoming ray48finFIG.5Bthat is absorbed, the incoming ray48einFIG.6Bhas a completely different behavior.

The diversion angle of the incoming ray48finFIG.6Bis smaller than the diversion angle of the incoming ray48finFIG.5Bbecause this angle is given by the distance between the left side of fringe A6and the right side of fringe B6. As the distance between the filtering pattern tilted with respect to the X-axis35aand the filtering pattern34bis longer inFIG.6Bthan the distance between the filtering pattern34aand the filtering pattern34binFIG.5B, this allows for the incoming ray48fwith smaller diversion angle inFIG.6Bto find a gap and go through all the filtering patterns missing all the fringes.

As the distance between the filtering pattern tilted with respect to the X-axis35aand the filtering pattern34bvaries along the X-axis, the distance varies between the filtering pattern tilted with respect to the X-axis35aand the filtering pattern34b. As a result, the diversion angle that is allowed through varies. At the points in the X-axis where the distance between the filtering pattern tilted with respect to the X-axis35aand the filtering pattern34bare equal or smaller than the distance between the filtering pattern34aand the filtering pattern34bonFIG.5Bthe gap is closed and the incoming ray48fis reflected as inFIG.5B.

The incoming ray48ggoes through the filtering pattern tilted with respect to the X-axis35a, passing just at the left of the fringe located at A9. The incoming ray48ghas a larger diversion angle than the diversion angle of the incoming ray48fbut instead of passing through as the incoming ray48f, the incoming ray48ghits the fringe located at C10and is absorbed.

The incoming ray48hgoes through the filtering pattern tilted with respect to the X-axis35a, passing just at the left of the fringe located at A12. The incoming ray48hhas a larger diversion angle than the diversion angle of the incoming ray48gand goes through all filtering patterns34b,34cexiting the filtering device with tilted filtering pattern with respect to the X-axis46just at the right of the fringe located at C13. The diversion angle of the incoming ray48hinFIG.6Bis smaller than the diversion angle of the incoming ray48hinFIG.5Bbecause this angle is given by the distance between the left side of fringe A12and the right side of fringe C13.

The incoming ray48igoes through the filtering pattern tilted with respect to the X-axis35a, passing just at the left of the fringe located at A13. The incoming ray48ihas a larger diversion angle than the incoming ray48hand also goes through all filtering patterns34b,34cexiting the filtering device with tilted filtering pattern with respect to the X-axis46between the fringes located at C14and C15. The diversion angle of the incoming ray48iinFIG.6Bis smaller than the diversion angle of the incoming ray48iinFIG.5Bbecause this angle is given by the distance between the left side of fringe A13and the left side of fringe B14.

The incoming ray48jgoes through the filtering pattern tilted with respect to the X-axis35a, passing just at the left of the fringe located at A14. The incoming ray48jhas a larger diversion angle than the diversion angle of the incoming ray48icausing it to hit the fringe located at B15and be absorbed.

The embodiment of the filtering device with tilted filtering pattern with respect to the X-axis46with one filtering pattern tilted with respect to the X-axis35aand two filtering patterns34b,34cas shown inFIG.6andFIG.6Bfeatures a position dependent behavior along the X-axis allowing unwanted incoming rays with various diversion angles to potentially go through, depending on the point of incidence along the X-axis. As a result, the laser source used must have better collimation than the collimation required to operate using the apparatus shown inFIG.5andFIG.5B.

To improve the performance of the filtering device with tilted filtering pattern with respect to the X-axis46, additional filtering patterns parallel to the filtering patterns34b,34ccan be used to guarantee that all laser beams produced by the available laser source hitting the filtering device with tilted filtering pattern with respect to the X-axis46at an unwanted angle are stopped.

FIG.7shows an embodiment of a filtering device with tilted filtering pattern with respect to the Y-axis47made with a filtering pattern tilted with respect to the Y-axis36aand one or more, two in the embodiment shown inFIG.7, filtering patterns34b,34c. The filtering pattern tilted with respect to the Y-axis36ais composed of a modified glass layer42aand a modified mirror layer43athat are distorted along the Y-axis to compensate for the inclination angle of installation.

The filtering patterns34b,34care identical, composed of the glass layer37b,37ccoated with the mirror layer38b,38cin the underside. The filtering patterns34b,34care assembled at a variable distance to each other with every filtering pattern34b,34cbeing placed in perfect alignment to each other so that when seen from above the mirror layers38b,38care all in perfect alignment.

Because the filtering pattern tilted with respect to the Y-axis36ais installed at a certain inclination angle, the modified glass layer42aand the modified mirror layer43aneed to be distorted along the Y-axis to compensate for the inclination angle of installation. This distortion extends all the structures along the Y-axis by a trigonometric factor given by the inverse of the cosine of the inclination angle the secant of the inclination angle. This distortion causes the total width of the modified glass layer42aand the modified mirror layer43ato increase and the position of every feature to move by the exact factor needed to compensate for the installation at the chosen inclination angle. This way, when seen from above, the modified glass layer42aperfectly matches the glass layers37b,37cand the modified mirror layer43aperfectly matches the mirror layers38b,38ccausing the filtering pattern tilted with respect to the Y-axis36ato be seen from above exactly as a filtering pattern34b,34c. Another way to explain this is that the projection of the filtering pattern tilted with respect to the Y-axis36aalong a line normal to the filtering patterns34b,34chas exactly the same shape and perfectly matches the filtering patterns34b,34c.

The filtering pattern tilted with respect to the Y-axis36aand the filtering patterns34b,34care assembled at variable distances to each other and the distance between the filtering pattern tilted with respect to the Y-axis36aand the filtering pattern34bvaries along the Y-axis because of the angle that the filtering pattern tilted with respect to the Y-axis36ais placed at, the distance being shorter towards the front and longer towards the back ofFIG.11.

FIG.7Ashows a cross-section of the filtering device with tilted filtering pattern with respect to the Y-axis47shown inFIG.7along the A-A section line. The filtering pattern tilted with respect to the Y-axis36aand the filtering patterns34b,34care sectioned by a plane perpendicular to the glass layers37b,37c. The section plane intercepts the modified glass layer42a, the modified mirror layer43aand the mirror layers38b,38c. The modified sealant layer44aand the sealant layers39b,39care seen directly below the modified mirror layer43aand the mirror layers38b,38crespectively.

The filtering pattern tilted with respect to the Y-axis36aand the filtering patterns34b,34care assembled at variable distances to each other and the distance between the filtering pattern tilted with respect to the Y-axis36aand the filtering pattern34bvaries along the Y-axis because of the angle that the filtering pattern tilted with respect to the Y-axis36ais placed at, the distance being shorter at the left and longer at the right ofFIG.7A.

All elements are placed in perfect alignment to each other so that when seen from above all fringes41a,41b,41cas well as the other structures of the modified mirror layer43a, the mirror layers38b,38c, the modified sealant layer44aand the sealant layers39b,39care all in perfect alignment.

A series of incoming rays48athrough48hand for the incoming rays that are reflected a series of corresponding reflected rays49dthrough49fare shown to illustrate the geometry and workings of the filtering device with tilted filtering pattern with respect to the Y-axis47.

To facilitate the identification of individual fringes a grid structure with letters and numbers has been created. This way to refer to the fringe41a, the reference A15can be used. Likewise, the fringe41bcan be appointed by the reference B13and the fringe41c, by the reference C8. Using this grid structure it is easy to note that the fringes A1, B1, and C1are in perfect alignment and likewise any fringes with different letters but with the same number are aligned.

Any set of fringes with different letters but with the same number that are aligned creates a channel that allows incoming rays to pass through. Any incoming ray hitting a fringe at any level is reflected.

The incoming ray48agoes through the filtering pattern tilted with respect to the Y-axis36aand other filtering patterns34b,34cas it is perpendicular to the filtering patterns and does not intercept any fringe, passing just to the right of the fringes located at position1. Likewise the incoming ray48balso goes through the filtering pattern tilted with respect to the Y-axis36aand other filtering patterns34b,34cas it is perpendicular to the filtering patterns and does not intercept any fringe, passing just to the left of the fringes located at position2. The incoming ray48aand the incoming ray48bpass at the edges of the channel1-2, between the fringes located at the positions1and2.

The incoming ray48cgoes through the filtering pattern tilted with respect to the Y-axis36aand other filtering patterns34b,34cat the maximum possible diversion angle with the normal to the filtering patterns allowed for a ray going through the channel between fringes2and3, passing just at the right of the fringe located at A2and to the left of the fringe located at C3. The diversion angle can be ascertained using the dashed line drawn perpendicular to the filtering patterns at the point where the incoming ray48cpasses the fringe located at A2.

The diversion angle of the incoming ray48cseen onFIG.7Ais larger than the diversion angle of the incoming ray48cseen onFIG.5A. This is because at the point of the incoming ray incidence the filtering pattern tilted with respect to the Y-axis36ais closer to the filtering pattern34cinFIG.7Athan the distance the filtering pattern34ais from the filtering pattern34conFIG.5Aand the shorter distance increases the allowed maximum angle.

As in the filtering device with tilted filtering pattern with respect to the Y-axis47shown inFIG.7Athe distance between the filtering pattern tilted with respect to the Y-axis36aand the filtering patterns34band34cvaries along the Y-axis, the geometry changes affecting the propagation path of incoming rays entering the device at different points. To better illustrate this effect a series of similar incoming rays are drawn at different points to ascertain the differences in the propagation path and clearances.

The incoming ray48dgoes through the filtering pattern tilted with respect to the Y-axis36apassing just at the left of the fringe located at A3and at an angle that allows it to just miss the fringe located at B3. The incoming ray48dhits the fringe located at C4and is reflected. The reflected ray49dgoes back and is absorbed by the sealant layer at the back of the fringe located at A5.

The incoming ray48egoes through the filtering pattern tilted with respect to the Y-axis36apassing just at the left of the fringe located at A6and at an angle that allows it to just miss the fringe located at B6. The incoming ray48ehas a smaller diversion angle than the incoming ray48d, hits the fringe located at C7and is reflected. The reflected ray49egoes back and is absorbed by the sealant layer at the back of the fringe located at A8.

The incoming ray48fgoes through the filtering pattern tilted with respect to the Y-axis36apassing just at the left of the fringe located at A9and at an angle that allows it to just miss the fringe located at B9. The incoming ray48fhas a smaller diversion angle than the incoming ray48e, hits the fringe located at C10and is reflected. The reflected ray49fgoes back and is absorbed by the sealant layer at the back of the fringe located at B10.

The incoming ray48ggoes through the filtering pattern tilted with respect to the Y-axis36apassing just at the left of the fringe located at A12and at an angle that allows it to just miss the fringe located at B12. The incoming ray48ghas a smaller diversion angle than the incoming ray48f, misses the fringe located at C13and exits the filtering device with tilted filtering pattern with respect to the Y-axis47.

The incoming ray48hgoes through the filtering pattern tilted with respect to the Y-axis36apassing just at the left of the fringe located at A14and at an angle that allows it to just miss the fringe located at B14. The incoming ray48ghas a smaller diversion angle than the incoming ray48f, misses the fringe located at C15and exits the filtering device with tilted filtering pattern with respect to the Y-axis47.

Note that the required incidence angle, the diversion angle, for incoming ray48fto miss the fringe at level B is smaller than the incidence angle of incoming ray48e. Likewise, the incidence angle for incoming ray48eto miss the fringe at level B is smaller than the incidence angle of incoming ray48d. This is a result of the gradual increase in the distance between the fringes caused by the angled installation of the filtering pattern tilted with respect to the Y-axis36a. As this continues eventually incoming ray48gis able to go through and exit the filtering device with tilted filtering pattern with respect to the Y-axis47. The next incoming ray48halso goes through and exits the filtering device with tilted filtering pattern with respect to the Y-axis47with some clearance to the fringe located at C15.

The embodiment of the filtering device with tilted filtering pattern with respect to the Y-axis47with one filtering pattern tilted with respect to the Y-axis36aand two filtering patterns34b,34cas shown inFIG.7andFIG.7Aallows unwanted incoming rays with various diversion angles to potentially go through, depending on the point of incidence along the Y-axis. As a result, the laser source used must have better collimation than the collimation required to operate using the apparatus shown inFIG.5andFIG.5A.

To improve the performance of the filtering device with tilted filtering pattern with respect to the Y-axis47, additional filtering patterns parallel to the filtering patterns34b,34ccan be used to guarantee that all laser beams produced by the available laser source hitting the filtering device with tilted filtering pattern with respect to the Y-axis47at an unwanted angle are stopped.

FIG.7Bshows a cross-section of an alternative embodiment of the filtering device with tilted filtering pattern with respect to the Y-axis47shown inFIG.7along the A-A section line. The filtering pattern tilted with respect to the Y-axis36aand the filtering patterns34b,34care sectioned by a plane perpendicular to the glass layers37b,37c. The section plane intercepts the modified glass layer42a, but differently from the embodiment show inFIG.7Athe modified mirror layer and the mirror layers are not applied and instead only the modified sealant layer44aand the sealant layers39b,39cthat absorb the laser light are present.

The filtering pattern tilted with respect to the Y-axis36aand the filtering patterns34b,34care assembled at variable distances to each other and the distance between the filtering pattern tilted with respect to the Y-axis36aand the filtering pattern34bvaries along the Y-axis because of the angle that the filtering pattern tilted with respect to the Y-axis36ais placed. All elements are placed in perfect alignment to each other so that when seen from above all fringes41a,41b,41cas well as the other structures of the modified mirror layer43a, the mirror layers38b,38c, the modified sealant layer44aand the sealant layers39b,39care all in perfect alignment.

A series of incoming rays48athrough48hare shown to illustrate the geometry and workings of the filtering device with tilted filtering pattern with respect to the Y-axis47.

To facilitate the identification of individual fringes a grid structure with letters and numbers has been created. This way to refer to the fringe41a, the reference A15can be used. Likewise, the fringe41bcan be appointed by the reference B13and the fringe41c, by the reference C8. Using this grid structure it is easy to note that the fringes A1, B1, and C1are in perfect alignment and likewise any fringes with different letters but with the same number are aligned.

Any set of fringes with different letters but with the same number that are aligned creates a channel that allows incoming rays to pass through. Any incoming ray hitting a fringe at any level is reflected.

The incoming ray48agoes through the filtering pattern tilted with respect to the Y-axis36aand other filtering patterns34b,34cas it is perpendicular to the filtering patterns and does not intercept any fringe, passing just to the right of the fringes located at position1. Likewise the incoming ray48balso goes through the filtering pattern tilted with respect to the Y-axis36aand other filtering patterns34b,34cas it is perpendicular to the filtering patterns and does not intercept any fringe, passing just to the left of the fringes located at position2. The incoming ray48aand the incoming ray48bpass at the edges of the channel1-2, between the fringes located at the positions1and2.

The incoming ray48cgoes through the filtering pattern tilted with respect to the Y-axis36aand other filtering patterns34b,34cat the maximum possible diversion angle with the normal to the filtering patterns allowed for a ray going through the channel between fringes2and3, passing just at the right of the fringe located at A2and to the left of the fringe located at C3. The diversion angle can be ascertained using the dashed line drawn perpendicular to the filtering patterns at the point where the incoming ray48cpasses the fringe located at A2.

The diversion angle of the incoming ray48cseen onFIG.7Bis larger than the diversion angle of the incoming ray48cseen onFIG.5A. This is because at the point of the incoming ray incidence the filtering pattern tilted with respect to the Y-axis36ais closer to the filtering pattern34cinFIG.7Bthan the distance the filtering pattern34ais from the filtering pattern34conFIG.5Aand the shorter distance increases the allowed maximum angle.

As in the filtering device with tilted filtering pattern with respect to the Y-axis47shown inFIG.7Bthe distance between the filtering pattern tilted with respect to the Y-axis36aand the filtering pattern34band34cvaries along the Y-axis, the geometry changes affecting the propagation path of incoming rays entering the device at different points. To better illustrate this effect a series of similar incoming rays are drawn at different points to ascertain the differences in the propagation path and clearances.

The incoming ray48dgoes through the filtering pattern tilted with respect to the Y-axis36apassing just at the left of the fringe located at A3and at an angle that allows it to just miss the fringe located at B3. The incoming ray48dhits the fringe located at C4and is absorbed.

The incoming ray48egoes through the filtering pattern tilted with respect to the Y-axis36apassing just at the left of the fringe located at A6and at an angle that allows it to just miss the fringe located at B6. The incoming ray48ehas a smaller diversion angle than the incoming ray48d, hits the fringe located at C7and absorbed.

The incoming ray48fgoes through the filtering pattern tilted with respect to the Y-axis36apassing just at the left of the fringe located at A9and at an angle that allows it to just miss the fringe located at B9. The incoming ray48fhas a smaller diversion angle than the incoming ray48e, hits the fringe located at C10and is absorbed.

The incoming ray48ggoes through the filtering pattern tilted with respect to the Y-axis36apassing just at the left of the fringe located at A12and at an angle that allows it to just miss the fringe located at B12. The incoming ray48ghas a smaller diversion angle than the incoming ray48f, misses the fringe located at C13and exits the filtering device with tilted filtering pattern with respect to the Y-axis47.

The incoming ray48hgoes through the filtering pattern tilted with respect to the Y-axis36apassing just at the left of the fringe located at A14and at an angle that allows it to just miss the fringe located at B14. The incoming ray48ghas a smaller diversion angle than the incoming ray48f, misses the fringe located at C15and exits the filtering device with tilted filtering pattern with respect to the Y-axis47.

Note that the required incidence angle, the diversion angle, for incoming ray48fto miss the fringe at level B is smaller than the incidence angle of incoming ray48e. Likewise, the incidence angle for incoming ray48eto miss the fringe at level B is smaller than the incidence angle of incoming ray48d. This is a result of the gradual increase in the distance between the fringes caused by the angled installation of the filtering pattern tilted with respect to the Y-axis36a. As this continues eventually incoming ray48gis able to go through and exit the filtering device with tilted filtering pattern with respect to the Y-axis47. The next incoming ray48halso go through and exit the filtering device with tilted filtering pattern with respect to the Y-axis47with some clearance to the fringe located at C15.

The embodiment of the filtering device with tilted filtering pattern with respect to the Y-axis47with one filtering pattern tilted with respect to the Y-axis36aand two filtering patterns34b,34cas shown inFIG.7andFIG.7Ballows unwanted incoming rays with various diversion angles to potentially go through, depending on the point of incidence along the Y-axis. As a result, the laser source used must have better collimation than the collimation required to operate using the apparatus shown inFIG.5andFIG.5A.

To improve the performance of the filtering device with tilted filtering pattern with respect to the Y-axis47, additional filtering patterns parallel to the filtering patterns34b,34ccan be used to guarantee that all laser beams produced by the available laser source hitting the filtering device with tilted filtering pattern with respect to the Y-axis47at an unwanted angle are stopped.

FIG.8shows a first embodiment of an apparatus to laser cut the graphene layer32applied over the substrate30. A laser source50produces a laser beam51athat is diverted using a mirror52through a lens53. As the laser beam51bexit the lens53it hits the filtering device45composed of several, three in the example ofFIG.8, filtering patterns34a,34b,34cthat are placed perfectly aligned with each other so that from the perspective of the laser beam51bthe filtering patterns appear as a single filtering pattern.

The reason for multiple filtering patterns is that due to physical limitations in the optic system the laser beam51bmay not be perfectly collimated and focused and therefore may have a degree of divergence producing rays that slowly spread out. The first filtering pattern34areflects the bulk of the unwanted portions of the laser beam51bgenerating a series of beam fringes54a,54bthat pass through and correspond to the places that need to be cut.

As explained in the above paragraph the beam fringes54a,54bare already in the shape of the intended cuts but due to the divergence of the laser beam51bthe beam fringes are still spreading out. The second filtering pattern34aand the third filtering pattern34care placed at a distance to the previous filtering pattern producing an assembly that works as a collimator. As the laser beam passes through the channels in one filtering pattern, the portions that pass near the edge of the reflective surface that are not perfectly aligned will hit the reflective surface in the next filtering pattern and will be removed producing a beam with increasing collimation and accuracy as the laser beam continues to the subsequent filtering patterns. More than three filtering patterns can be used if needed according to the level of collimation required. The last filtering pattern34cis placed as close to the graphene layer32as feasible to produce a laser cut55as accurate as possible in the graphene layer32.

FIG.9shows the laser cuts55a,55bon the graphene layer32applied over the substrate30produced by the apparatus shown inFIG.8.

FIG.10shows a cut path56produced when the mirror52amoves to deflect the laser beam51agenerated by the laser source50. The lens53deflects the laser beam51aand corrects the angle at the point of incidence so that after leaving the lens53the laser beam51ahits the filtering device45composed of several, three in the example ofFIG.10, filtering patterns34a,34b,34cin a straight angle or at an angle as straight as possible producing beam fringes54athat hit the graphene layer32previously applied over the substrate30.

To better illustrate the cut path56produced when the mirror52moves to deflect the laser beam51a,FIG.10shows an overlay with the mirror52bin the same position as seen on previousFIG.8. In the overlay shown inFIG.10, the produced laser beam51bhits the first filtering pattern34aand subsequent filtering patterns34b,34cat a straight angle and the produced beam fringes54bhit the graphene layer32and produce the intended laser cut55at the beginning of the cut path56. The beam fringes54aproduced by the deflected laser beam51ahit the graphene layer32at the end of the cut path56.

FIG.11shows the cut path56on the graphene layer32applied over the substrate30produced by the apparatus shown inFIG.12.

FIG.12shows a slightly different possibility where a prism57is used instead of the mirror to deflect the laser beam51through the lens53. As the laser beam51exits the lens53it hits the filtering device45composed of several, three in the example ofFIG.12, filtering patterns34a,34b,34cthat are placed perfectly aligned with each other so that from the perspective of the laser beam51the filtering patterns appear as a single filtering pattern. The first filtering pattern34areflects the bulk of the unwanted portions of the laser beam51generating the beam fringes54that hit the graphene layer32previously applied over the substrate30producing the intended laser cut55.

FIG.13shows the apparatus to laser cut the graphene layer32applied over the substrate30from a different angle to show additional detail. The laser beam51aproduced by the laser source50is diverted in the mirror52, passes through the lens53and hits the filtering device45. A reflected laser beam59ais produced when the laser beam51bhits the mirror layer38aof the filtering pattern34a, and the mirror layers of the subsequent filtering patterns34b,34c.

As the filtering pattern34ais placed exactly perpendicular to the laser beam51b, the reflected laser beam59areturns in the same path in reverse order going through the lens53and the mirror52. To prevent the reflected laser beam59ato return to the laser source50potentially causing damage to the laser source50, a partial mirror58is placed between the laser source50and the mirror52in such a way that the laser beam51acoming from the laser source50passes through but the reflected laser beam59bcoming from the mirror52is reflected 90 degrees so it can be safely absorbed by an assimilator60.

FIG.14shows a slightly different arrangement to safely absorb the reflected laser beam59bin the assimilator60. The laser beam51aproduced by the laser source50is diverted in the mirror52, passes through the lens53and hits the filtering device with tilted filtering pattern with respect to the X-axis46.

The bulk of the reflected laser beam59ais produced when the laser beam51bhits the modified mirror layer43aof the filtering pattern tilted with respect to the X-axis35a. There are secondary reflections in the mirror layers38b,38cof the subsequent filtering patterns34b,34cbut as these secondary reflections are caused by divergence of the laser beam51bthey are substantially less powerful and do not need to be considered a threat to the laser source50.

As the filtering pattern tilted with respect to the X-axis35ais placed with its normal at a small angle to the laser beam51b, the reflected laser beam59areturns in a slightly different path than the path taken by the laser beam51b. The reflected laser beam59agoes through the lens53and the mirror52but hits the mirror52at a different point and at a different angle. As a result the reflected laser beam59bskips the laser source50and goes directly to the assimilator60to be absorbed.

The angle between the normal of the filtering pattern tilted with respect to the X-axis35aand the laser beam51b, must be relatively small to avoid big variations in distance between both ends of the filtering pattern tilted with respect to the X-axis35aand the filtering pattern34bthat could impair the collimation function of the filtering device with tilted filtering pattern with respect to the X-axis46.

The laser beam51bportions that are not reflected create many beam fringes54that hit the graphene layer32and produce the intended laser cut55.

FIG.19shows the end result of the laser cutting on the graphene layer applied over the substrate30. As the cutting is completed a processed graphene layer62is produced with a pair of terminals63aand63b. In the design shown inFIG.19the terminals63aand63bare fully separated from each other and remain connected to a series of alternated fringes64a,64b, etc. in such a way that the terminal63ais connected to the fringe64abut not to the next adjacent fringe64b.Similarly, the terminal63bis connected to the fringe64bbut not to fringe64a.The terminals63aand63bare also connected to the respective under contacts33aand33bunder the substrate30through the perforations31a,31bin such a way that the terminal63ais connected to the under contact33abut not to the under contact33band the terminal63bis connected to the under contact33bbut not to the under contact33a. To facilitate the visualization of the under contacts33aand33btwo circular cutouts have been made in the substrate30at the appropriate points.

FIG.20shows an alternate end result of the laser cutting on the graphene layer applied over the substrate30. As the cutting is completed using an appropriate set of filtering patterns the processed graphene layer62is produced with a set of unconnected fringes65a,65b, etc. that are not connected to any of the terminals63aand63b. In the example ofFIG.20, the terminals63aand63bare fully separated from each other and remain connected to a series of alternated fringes64a,64b, etc. in such a way that one unconnected fringe65a, is placed between two consecutive fringes64a,64b, connected to the terminals63aand63brespectively. Similarly, the unconnected fringe65bis placed between fringe64bconnected to the terminals63band the next fringe connected to the terminal63aand so on.

FIG.21shows an element stack66that is produced when multiple processed graphene layers62a,62b,62c,62d, etc. are stacked to increase the total device capacity. For better stability the first processed graphene layer62ato be placed in the element stack66is constructed on a base67amade of a thicker, sturdier material than the material used in the substrate30b,30c, etc. used to support the other processed graphene layers62b,62c,62dincluded in the element stack66.

The individual layers are just simply stacked on top of each other taking care to align all the layers so that for example the under contact33din the second layer is placed exactly above the terminal63bin the first layer. Similarly, the under contact33fin the third layer is placed exactly above the terminal63din the second layer. The same applies for the terminals63gon the other side and the terminals63f,63hon other layers.

FIG.22shows a supercapacitor assembly68that is produced when a cover69is placed over the base67containing one processed graphene layer62or one element stack to fully encase the structure inside a protective environment. A pair of metallic contacts70a, and70bare placed in contact with the terminals63a, and63brespectively to provide a sturdy electric contact to supply power to external devices. To facilitate the visualization of other components, the cover69was drawn transparent.

First the perforations31are made at both ends of the substrate30as seen inFIG.1. Then the graphene layer32is applied on top of the substrate30in such a way to cover and flow through and cover all the perforations31. The application of the graphene layer32can be done in one or more steps applying a single layer of the intended thickness or applying successive layers of an adequate thickness and letting it dry before applying the next layer until the intended thickness is achieved. To ensure that the graphene layer32has a good bond to the substrate30, a surface treatment such as surface plasma eroding can be applied to the substrate30if necessary.

As shown inFIG.2, under contacts33made out of the same material used to create the graphene layer32are made in the underside of the graphene layer32. The previously done perforations31create a series of bridges that are filled with the same material as the graphene layer32and the under contacts33allowing the graphene layer32and the under contacts33to remain physically and electrically connected across the substrate30.

FIG.3shows an isometric view of the graphene layer32applied over the substrate30showing the perforations31and the under contacts33andFIG.4shows an embodiment of the filtering pattern34that is composed of the glass layer37with portions of the glass layer37coated with the mirror layer38along the underside of the glass layer37with the mirror layer38formed in a pattern.

The laser cutting operation may be performed using any one of filtering devices45,46, and47shown inFIG.5-7Bor other embodiments. The filtering patterns may be of any suitable design to develop the desired properties of the supercapacitor or other products.

FIG.8shows the basic cutting method. The laser source50produces the laser beam51athat is diverted using the mirror52through the lens53. As the laser beam51bexits the lens53it hits several, three in the example ofFIG.8, filtering patterns34a,34b,34cthat are placed perfectly aligned with each other so that from the perspective of the laser beam51bthe filtering patterns appear as a single filtering pattern. By using multiple filtering patterns any degree of divergence producing rays that slowly spread out is eliminated.

The first filtering pattern34areflects the bulk of the unwanted portions of the laser beam51bgenerating many beam fringes54a,54bthat pass through and correspond to the places that will be cut. The second filtering pattern34aand the third filtering pattern34care placed at a distance to the previous filtering pattern producing an assembly that works as a collimator. As the laser beam passes through the channels in one filtering pattern, the portions that pass near the edge of the reflective surface that are not perfectly aligned hit the reflective surface in the next filtering pattern and are removed producing a beam with increasing collimation and accuracy as the laser beam continues to the subsequent filtering patterns with last filtering pattern34cplaced as close to the graphene layer32as achievable to produce the laser cut55as accurately as possible in the graphene layer32as shown inFIG.9.

As shown inFIG.10, the mirror pivots indicated in a first position52aand in a second position as52bto divert the laser beam51balong the Y axis. The substrate30with the applied graphene layer32and the filtering patterns34a,34b,34cmove together in unison to allow the laser beam51ato reach different points across the X axis. As the laser beam51amoves and hits different points in the filtering patterns34a,34b,34cthe beam fringes54a,54balter accordingly keeping the precise pattern that needs to be produced at the laser cut55point in the graphene layer32below. To maximize cutting efficiency, the laser beam51ais produced orders of magnitude wider than the smallest dimensions in the filtering patterns34a,34b,34cspreading the laser power over a larger area and producing a plurality, which might be several thousands, of beam fringes54a,54bthat have each a tiny portion of the total energy contained in the laser beam51a. These low power beam fringes54a,54bcan cut the graphene layer32more gently than a concentrated thin laser beam would, taking smaller chunks of material at each pass. However, as there are a plurality, which might be several thousands, of beam fringes54a,54bthe combined effect produces a faster and more reliable result than a single more powerful laser beam could possibly produce.

As shown inFIG.10, the cut path56is produced after the lens53deflects the laser beam51aand corrects the angle at the point of incidence so that after leaving the lens53the laser beam51ahits the first filtering pattern34aand subsequent filtering patterns34b,34cin a straight angle or at an angle as straight as possible producing beam fringes54athat hit and cut the graphene layer32previously applied over the substrate30in the design of the filtering patterns34a,34b, and34cof the filtering device45.

As shown inFIG.12the mirror shown in previousFIG.8andFIG.10, can be replaced by the prism57and operate in the same way as described above forFIG.8andFIG.10with similar results.

FIG.13shows the reflected laser beam59aproduced when the laser beam51bhits the mirror layer38aof the filtering pattern34aand the mirror layers of the subsequent filtering patterns34b,34c. Because the filtering pattern34ais placed exactly perpendicular to the laser beam51b, the reflected laser beam59areturns in the same path in reverse order going through the lens53and the mirror52so to prevent damage to the laser source50, the partial mirror58is placed between the laser source50and the mirror52in such a way that the laser beam51acoming from the laser source50passes through but the reflected laser beam59bcoming from the mirror52is reflected 90 degrees so it can be safely absorbed by the assimilator60.

The mirror52pivots to divert the laser beam51balong the Y axis and the substrate30with the applied graphene layer32and the filtering patterns34a,34b,34cmove together in unison to allow the laser beam51bto reach different points across the X axis. As this process occurs the reflected laser beam59bchanges accordingly depending on the pattern at the particular point it hits in the filtering patterns34a,34b,34c. The reflected laser beam59bis reflected back in the mirror52and reflected again in the partial mirror58and continues to be safely absorbed by the assimilator60.

FIG.14shows a slightly different arrangement to safely absorb the reflected laser beam59bin the assimilator60. As the filtering pattern tilted with respect to the X-axis35ais placed with its normal at a small angle to the laser beam51b, the reflected laser beam59areturns in a slightly different path than the path taken by the laser beam51b. The reflected laser beam59agoes through the lens53and the mirror52but hits the mirror52at a different point and at a different angle. As a result the reflected laser beam59bskips the laser source50and goes directly to the assimilator60to be absorbed.

The angle between the normal of the filtering pattern tilted with respect to the X-axis35aand the laser beam51b, must be relatively small to avoid big variations in distance between both ends of the filtering pattern tilted with respect to the X-axis35aand the filtering pattern34bthat could impair the collimation function of the filtering device with tilted filtering pattern with respect to the X-axis46.

The mirror52pivots to divert the laser beam51balong the Y axis and the substrate30with the applied graphene layer32and the filtering patterns34a,34b,34cmove together in unison to allow the laser beam51bto reach different points across the X axis. As this process occurs the reflected laser beam59bis reflected back in the mirror52and continues to be safely absorbed by the assimilator60.

As the laser beam51bmoves and hits different points in the filtering pattern tilted with respect to the X-axis35aand the filtering patterns34b,34cthe beam fringes54alter accordingly keeping the precise pattern that needs to be produced at the laser cut55point in the graphene layer32below. To maximize cutting efficiency, the laser beam51bis produced orders of magnitude wider than the smallest dimensions in the filtering pattern tilted with respect to the X-axis35aand the filtering patterns34b,34cspreading the laser power over a larger area and producing a plurality, which might be several thousands, of beam fringes54that each have a tiny portion of the total energy contained in the laser beam51b.These low power beam fringes54can cut the graphene layer32more gently than a concentrated thin laser beam would, taking smaller chunks of material at each pass. However, as there are a plurality, which might be several thousands, of beam fringes54the combined effect produces a faster and more reliable result than a single more powerful laser beam could possibly produce.

FIG.19shows the end result of the laser cutting on the graphene layer applied over the substrate30. As the cutting is completed the processed graphene layer62is produced with the pair of terminals63aand63b. In the design shown inFIG.19the terminals63aand63bare fully separated from each other and remain connected to the series of alternated fringes64a,64b, etc. in such a way that the terminal63ais connected to the fringe64abut not to the next adjacent fringe64b. Similarly, the terminal63bis connected to the fringe64bbut not to the fringe64a. The terminals63aand63bare also connected to the respective under contacts33aand33bunder the substrate30through the perforations31a,31bin such a way that the terminal63ais connected to the under contact33abut not to the under contact33band the terminal63bis connected to the under contact33bbut not to the under contact33a. To facilitate the visualization of the under contacts33aand33btwo circular cutouts have been made in the substrate30at the appropriate points.

Any two adjacent fringes64aand64bimplement a unit capacitor. As the alternate fringes are connected to separate terminals63aand63bthe total arrangement works as thousands of capacitors connected in parallel. The under contacts33aand33bplaced directly under the terminals63aand63band electrically connected to their respective terminals63aand63bwork as an easy way to stack multiple layers of thousands of capacitors connected in parallel.

FIG.20shows an alternate end result of the laser cutting on the graphene layer applied over the substrate30. As the cutting is complete using an appropriate set of filtering patterns the processed graphene layer62is produced with the set of unconnected fringes65a,65b, etc. that are not connected to any of the terminals63aand63b. In the example ofFIG.20, the terminals63aand63bare fully separated from each other and remain connected to a series of alternated fringes64a,64b, etc. in such a way that one unconnected fringe65a, is always placed between two consecutive fringes64a,64b, connected to the terminals63aand63brespectively. Similarly, the unconnected fringe65bis placed between fringe64bconnected to the terminals63band the next fringe connected to the terminal63a.

The two adjacent fringes64aand64bthat are connected to the terminals63aand63btogether with the unconnected fringe65ain the middle implement two unit capacitors arranged in series. One capacitor between the fringe64aand the unconnected fringe65aand one capacitor between the unconnected fringe65aand the fringe64b. As the alternate fringes64aand64bare connected to separate terminals63aand63bthe total arrangement works as thousands of paired capacitors connected in series that are connected in parallel. The under contacts33aand33bplaced directly under the terminals63aand63band electrically connected to their respective terminals63aand63bwork as an easy way to stack multiple layers of thousands of 2 capacitors connected in series that are connected in parallel.

FIG.21shows the element stack66that is produced when multiple processed graphene layers62a,62b,62c,62d, etc. are stacked to increase the total device capacity. For better stability the first processed graphene layer62ato be placed in the element stack66is constructed on the base67amade of a thicker, sturdier material than the material used in the substrate30b,30c, etc. used to support the other processed graphene layers62b,62c,62dincluded in the element stack66.

The individual layers are just simply stacked on top of each other taking care to align all the layers so that for example the under contact33din the second layer is placed exactly above the terminal63bin the first layer. Similarly, the under contact33fin the third layer is placed exactly above the terminal63din the second layer. The same applies for the terminals63gon the other side and the terminals63f,63hon other layers.

FIG.22shows the supercapacitor assembly68that is produced placing the cover69over the base67containing one processed graphene layer62or one element stack to fully encase the structure inside a protective environment. The pair of metallic contacts70a, and70bis placed in contact with the terminals63a, and63brespectively to provide a sturdy electric contact to supply power to external devices.

Second Embodiment

FIG.15shows an alternative embodiment of the present invention that offers the significant advantage of allowing faster processing using multiple laser beams. Many laser beams can be used simultaneously provided that they are sufficiently separated to avoid interference and proper time for heat dissipation. In the example ofFIG.15, only 4 laser beams are drawn to avoid cluttering. The laser source50a,50b,50c,50dis placed directly above the filtering patterns34a,34b,34cand the graphene layer32applied over the substrate30. The laser beam51a,51b,51c,51dportions that are not reflected create many beam fringes54a,54b,54c,54d,54ethat hit the graphene layer32and produce the intended laser cut55a,55b,55c,55das illustrated inFIG.16.

The reason for multiple filtering patterns is that the laser beams may not be perfectly collimated and focused and therefore may have a degree of divergence producing rays that slowly spread out. The first filtering pattern34areflects the bulk of the unwanted portions of the laser beams generating many beam fringes that pass through and correspond to the places that will be cut.

As explained in the above paragraph the beam fringes are already in the shape of the intended cuts but due to the divergence of the laser beams the beam fringes are still spreading out. The second filtering pattern34band the third filtering pattern34care placed at a distance to the previous filtering pattern producing an assembly that works as a collimator. As the laser beams pass through the channels in one filtering pattern, the portions that pass near the edge of the reflective surface that are not perfectly aligned will hit the reflective surface in the next filtering pattern and will be removed producing a beam with increasing collimation and accuracy as the laser beam continues to the subsequent filtering patterns. More than three filtering patterns can be used if needed according to the level of collimation required. The last filtering pattern34cis placed as close to the graphene layer32as feasible to produce the laser cut55as accurately as possible in the graphene layer32.

The reflected laser beam59a,59b,59c,59dis produced when the laser beam51a,51b,51c,51dhits the mirror layer38aof the filtering pattern34aand the mirror layers of the subsequent filtering patterns34b,34c. As the filtering pattern34ais placed perpendicular to the laser beam51a,51b,51c,51d, the reflected laser beam59a,59b,59c,59dreturns in the same path than the path taken by the laser beam51a,51b,51c,51d. To prevent the reflected laser beam59a,59b,59c,59dto return to the laser source50a,50b,50c,50dand damage the laser source50a,50b,50c,50da long partial mirror61is placed at a 45 degree angle to the laser beam51a,51b,51c,51din such a way that the laser beam51a,51b,51c,51dcoming from the laser source50a,50b,50c,50dpasses through but the reflected laser beam59a,59b,59c,59dis reflected 90 degrees to a direction where it can be safely absorbed.

FIG.16shows the laser cuts55a,55b,55c,55don the graphene layer32applied over the substrate30produced by the apparatus shown inFIG.15.

FIG.17shows a slightly different arrangement to safely absorb the reflected laser beam59in the assimilator60. The laser source50is placed directly above the filtering device with tilted filtering pattern with respect to the X-axis46and the graphene layer32applied over the substrate30. The filtering device with tilted filtering pattern with respect to the X-axis46is composed of one filtering pattern tilted with respect to the X-axis35aand several, two in the example ofFIG.17, filtering patterns34b,34c.

The laser beam51portions that are not reflected in the filtering pattern tilted with respect to the X-axis35acreate many beam fringes54that hit the graphene layer32and produce the intended laser cut55.

The bulk of the reflected laser beam59is produced when the laser beam51hits the modified mirror layer43aof the filtering pattern tilted with respect to the X-axis35a. The filtering pattern tilted with respect to the X-axis35ais placed with its normal at a small angle to the laser beam51to have the reflected laser beam59return in a slightly different path than the path taken by the laser beam51. As a result the reflected laser beam59skips the laser source50and continues directly to the assimilator60where it is safely absorbed.

The secondary reflections in the mirror layers of the subsequent filtering patterns34b,34care caused by divergence of the laser beam51and are therefore substantially less powerful and are no threat to the laser source50.

The angle between the normal of the filtering pattern tilted with respect to the X-axis35aand the laser beam51, must be relatively small to avoid big variations in distance between both ends of the filtering pattern tilted with respect to the X-axis35aand the filtering pattern34bthat could impair the collimation function of the filtering device with tilted filtering pattern with respect to the X-axis46.

FIG.18shows a variation of the arrangement ofFIG.17. In the example ofFIG.18, the filtering device with tilted filtering pattern with respect to the Y-axis47is used and the filtering pattern tilted with respect to the Y-axis36ais placed at an angle to the laser beam51a,51brelative to the width along the Y-axis. The axis of the angle can be ascertained using the under contact33as reference.

FIG.18also differs fromFIG.17by the fact that two laser beams51a,51bare used in parallel to reduce manufacturing time. More than two laser beams could be used to further reduce the manufacturing time inFIG.18as well as more than one inFIG.17if desired. The drawings inFIG.17were made with one laser beam and inFIG.18with two laser beams for simplicity and to avoid clutter that would make it harder to show all the detail.

The arrangement inFIG.18offers the significant advantage of allowing faster processing using multiple laser beams. Many laser beams can be used simultaneously provided that they are sufficiently separated to avoid interference and proper time for heat dissipation. The laser source50a,50bis placed directly above the filtering device with tilted filtering pattern with respect to the Y-axis47that is composed of one filtering pattern tilted with respect to the Y-axis36aand several, two in the example of filtering patterns34b,34c. The laser beam51a,51bportions that are not reflected by the filtering pattern tilted with respect to the Y-axis36acreate many beam fringes54a,54bthat hit the graphene layer32applied over the substrate30and produce the intended laser cut55a,55b.

The bulk of the reflected laser beam59a,59bis produced when the laser beam51a,51bhits the modified mirror layer43aof the filtering pattern tilted with respect to the Y-axis36a. As the filtering pattern tilted with respect to the Y-axis36ais placed with its normal at a small to the laser beam51a,51b, the reflected laser beam59a,59breturns in a slightly different path than the path taken by the laser beam51a,51b. As a result the reflected laser beam59a,59bskips the laser source50a,50band continues to a point where it is safely absorbed.

There are secondary reflections in the mirror layers of the subsequent filtering patterns34b,34cbut as these secondary reflections are caused by divergence of the laser beam51a,51bthey are substantially less powerful and are not a threat to the laser source50a,50b.

The advantage of the arrangement shown inFIG.18is that it is simpler and requires less components is cheaper than the arrangement described inFIG.14. The disadvantage of the arrangement shown inFIG.18is that the small angle between the normal of the filtering pattern tilted with respect to the Y-axis36aand the laser beam51a,51b, results in a small angle between the laser beam51a,51band the reflected laser beam59a,59bthat in turn forces the laser source50a,50bto be placed at a greater distance to the filtering pattern tilted with respect to the Y-axis36aso that the reflected laser beam59a,59bhas sufficient distance to skip the laser source50a,50b.

The preparation of the substrate30with the perforations31and the application of the graphene layer32on top of the substrate30and creating under contacts33made out of the same material used to create the graphene layer32as well as the preparation and operation of the filtering pattern34are made as described in the operation of the first embodiment of the present invention.

InFIG.15four laser beams are used simultaneously to cut the desired pattern into the graphene layer32. More or less laser beams could instead be used but to avoid cluttering the explanation is made for a typical case with four laser beams.

The laser sources50a,50b,50c,50dare placed directly above the filtering patterns34a,34b,34cand the graphene layer32applied over the substrate30. The laser beams51a,51b,51c,51dportions that are not reflected create many beam fringes54a,54b,54c,54d,54ethat hit the graphene layer32and produce the intended laser cuts55a,55b,55c,55d.

The reflected laser beams59a,59b,59c,59dare produced when the laser beams51a,51b,51c,51dhit the mirror layer38aof the filtering pattern34aand the mirror layers of the subsequent filtering patterns34b,34c. As the filtering pattern34ais placed perpendicular to the laser beams51a,51b,51c,51d, the reflected laser beams59a,59b,59c,59dreturn in the same path as the paths taken by the respective laser beams51a,51b,51c,51d. The long partial mirror61allows the laser beams51a,51b,51c,51dcoming from the laser sources50a,50b,50c,50dto pass through but deflects the reflected laser beams59a,59b,59c,59d90 degrees to a direction where they can be safely absorbed preventing potential damage to the laser sources50a,50b,50c,50d.

The laser sources50a,50b,50c,50dcan move in the X and Y axis relative to the graphene layer32that is kept at the same relative position to the filtering patterns34a,34b, and34cand the long partial mirror61.

As the laser sources50a,50b,50c,50dmove, the laser beams51a,51b,51c,51dhit different points in the filtering patterns34a,34b,34ccausing the beam fringes54a,54b,54c,54dto alter accordingly keeping the precise pattern that needs to be produced at the laser cut55a,55b,55c,55dpoints in the graphene layer32below. To maximize cutting efficiency, the laser beams51a,51b,51c,51dare produced orders of magnitude wider than the smallest dimensions in the filtering patterns34a,34b,34cspreading the laser power over a larger area and producing a plurality, which might be several thousands, of beam fringes54a,54b,54c,54dthat have each a tiny portion of the total energy contained in the laser beams. These low power beam fringes can cut the graphene layer more gently than a concentrated thin laser beam would, taking smaller chunks of material at each pass. However, as there are thousands of beam fringes the combined effect produces a faster and more reliable result than a single more powerful laser beam could possibly produce.

In the example ofFIG.17, the filtering pattern tilted with respect to the X-axis35ais placed at an angle to the laser beam51relative to the X axis along the length of the filtering pattern tilted with respect to the X-axis35a. The axis of the angle can be ascertained using the under contact33as reference.

The arrangement inFIG.17requires the filtering pattern tilted with respect to the X-axis35ato be slightly modified. The filtering pattern tilted with respect to the X-axis35amust be constructed taking the angle between the normal of the filtering pattern tilted with respect to the X-axis35aand the laser beam51into consideration. This is easily achieved altering the pattern in the filtering pattern tilted with respect to the X-axis35ain such a way that when seen by the laser beam51perspective, at an angle, it presents exactly the same pattern as the other filtering patterns34band34cthat are seen straight on. The laser beam51portions that are not reflected create many beam fringes54that hit the graphene layer32and produce the intended laser cut55.

The laser source50can move in the X and Y axis relatively to the graphene layer32that is kept at the same relative position to the filtering device with tilted filtering pattern with respect to the X-axis46.

As the laser source50moves, the laser beam51hits different points in the filtering pattern tilted with respect to the X-axis35aand the filtering patterns34b,34ccausing the beam fringes54to alter accordingly keeping the precise pattern that needs to be produced at the laser cut55point in the graphene layer32below. To maximize cutting efficiency, the laser beam51is produced orders of magnitude wider than the smallest dimensions in the filtering pattern tilted with respect to the X-axis35aand the filtering patterns34b,34cspreading the laser power over a larger area and producing a plurality, which might be several thousands, of beam fringes54that have each a tiny portion of the total energy contained in the laser beam. These low power beam fringes can cut the graphene layer more gently than a concentrated thin laser beam would, taking smaller chunks of material at each pass. However, as there are a plurality, which might be thousands of beam fringes the combined effect produces a faster and more reliable result than a single more powerful laser beam could possibly produce.

The advantage of the arrangement shown inFIG.17is that it is simpler and requires less components is cheaper than the arrangement described inFIG.14. The disadvantage of the arrangement shown inFIG.17is that the small angle between the normal of the filtering pattern tilted with respect to the X-axis35aand the laser beam51, results in a small angle between the laser beam51and the reflected laser beam59that in turn forces the laser source50to be placed at a greater distance to the filtering pattern tilted with respect to the X-axis35aso that the reflected laser beam59has sufficient distance to skip the laser source50.

InFIG.18two laser beams are used simultaneously to cut the desired pattern into the graphene layer32. More or less laser beams could instead be used but to avoid cluttering the explanation is made for a typical case with two laser beams.

The laser sources50a,50bare placed directly above the filtering device with tilted filtering pattern with respect to the Y-axis47and the graphene layer32applied over the substrate30. The laser beams51a,51bportions that are not reflected by the filtering pattern tilted with respect to the Y-axis36acreate many beam fringes54a,54bthat hit the graphene layer32and produce the intended laser cuts55a,55b.

The bulk of the reflected laser beam59a,59bis produced when the laser beam51a,51bhits the modified mirror layer43aof the filtering pattern tilted with respect to the Y-axis36a. As the filtering pattern tilted with respect to the Y-axis36ais placed with its normal at a small to the laser beam51a,51b, the reflected laser beam59a,59breturns in a slightly different path than the path taken by the laser beam51a,51b. As a result the reflected laser beam59a,59bskips the laser source50a,50band continues to a point where it is safely absorbed.

There are secondary reflections in the mirror layers of the subsequent filtering patterns34b,34cbut as these secondary reflections are caused by divergence of the laser beam51a,51bthey are substantially less powerful and are not a threat to the laser source50a,50b.

The laser sources50a,50bcan move in the X and Y axis relatively to the graphene layer32that is kept at the same relative position to the filtering device with tilted filtering pattern with respect to the Y-axis47.

As the laser sources50a,50bmove, the laser beams51a,51bhit different points in the filtering pattern tilted with respect to the Y-axis36aand the filtering patterns34b,34ccausing the beam fringes54a,54bto alter accordingly keeping the precise pattern that needs to be produced at the laser cut55a,55bpoints in the graphene layer32below. To maximize cutting efficiency, the laser beams51a,51bare produced orders of magnitude wider than the smallest dimensions in the filtering pattern tilted with respect to the X-axis35aand the filtering patterns34b,34cspreading the laser power over a larger area and producing a plurality, which might be several thousands, of beam fringes54a,54bthat have each a tiny portion of the total energy contained in the laser beams. These low power beam fringes can cut the graphene layer more gently than a concentrated thin laser beam would, taking smaller chunks of material at each pass. However, as there are a plurality, which might be thousands, of beam fringes the combined effect produces a faster and more reliable result than a single more powerful laser beam could possibly produce.

CONCLUSION

A new method to produce parts with laser cutting technology using a filtering pattern is presented. This method can produce parts with a very high number of fine details or in other words, the part can be fully covered by a pattern of detailed structures with details having dimensions 3 to 5 orders of magnitude smaller than the overall dimensions of the part and these parts can be produced in a reasonable timeframe that is several thousand times faster than what can be achieved using traditional laser cutting methods.

The proposed filtering pattern serves multiple purposes: a it serves as a pattern to the intended detail that must be cut; b it serves as a collimator that avoids or drastically reduces problems caused by laser beam divergence such as damage to unintended areas; c it serves as a beam splitter that dynamically splits a wide laser beam into several thousand very narrow child laser beams that are more suitable for cutting very delicate structures; d it serves as a means to allow simplification of the optics needed to focus the laser beam and assimilate imprecisions of the positioning control mechanism; e it creates flexibility in the production line where multiple filtering patterns using different mask designs can be easily made and these designs can be cheaply and quickly interchanged in the manufacturing line to produce a variety of devices to cope with different customer demands.

The proposed invention is very suitable to produce high performance double layer graphene supercapacitors that require a very high number of very fine detailed structures, such as fringes, to be constructed at very small separation from each other. Another requirement is a very high aspect ratio between the thickness of the individual fringes to accommodate as many fringes as possible in the width or length of the graphene slab and the height of the individual fringes so the fringes extend all the way from the bottom to the top of the graphene slab.

The proposed invention allows the construction of high performance, energy dense graphene supercapacitor in a timeframe compatible with mass production, several thousand times faster than other methods can. As a result, the produced devices can be manufactured at an affordable cost that allows them to be competitive in the market with other electricity storage devices.

While the invention has been disclosed by this specification, including its accompanying drawings and examples, various equivalents, modifications and improvements will be apparent to the person skilled in the art. Such equivalents, modifications and improvements are also intended to be encompassed by the following claims.