Apparatus and method for laser retexturing

Abstract

Apparatuses and methods are described herein for laser retexturing of a joined object. The apparatus comprises a joiner for joining a first object with a second object into the joined object, wherein the joined object comprises a surface defect, and a laser apparatus for receiving the joined object, wherein the laser apparatus comprises a laser, and wherein the laser is structured to texture a surface of the joined object comprising the surface defect.

Description

APPARATUS AND METHOD FOR LASER RETEXTURINGFIELD OF THE INVENTION

[0001] The present invention relates to an apparatus for laser retexturing and a method of use.BACKGROUND OF THE INVENTION

[0002] Current methods and apparatuses for joining objects, such as ultrasonic welding techniques, are capable of creating high strength joints between the two objects. However, in creating such high-strength joints, portions of the joined object generally deform, resulting in defects such as surface finish and texturing inconsistencies. This is particularly problematic in applications where maintaining a uniform appearance and surface finish of the individual objects is crucial, such as in the manufacturing of aesthetic products or precision components. Moreover, the existing techniques for mitigation and removal of such defects often require mechanical postprocessing steps, such as sanding or polishing, to restore the desired surface finish, which adds complexity, time, and cost to the production process. Therefore, there is a need for an improved method and apparatus that can achieve strong joints between objects while preserving the uniformity of the surface finish and texture and reduce the need for post-processing operations.SUMMARY OF THE INVENTION

[0001] The following presents a simplified summary of one or more embodiments of the present invention, in order to provide a basic understanding of such embodiments. This summary is not an extensive overview of all contemplated embodiments and is intended to neither identify key or critical elements of all embodiments nor delineate the scope of any or all embodiments. Its sole purpose is to present some concepts of one or more embodiments of the present invention in a simplified form as a prelude to the more detailed description that is presented later.

[0002] In one aspect, an apparatus for laser retexturing of a joined object is presented. The apparatus may include a joiner for joining a first object with a second object into the joined object, wherein the joined object may include a surface defect, and a laser apparatus for receiving the joined object, wherein the laser apparatus may include a laser, and wherein the laser is structured to texture a surface of the joined object comprising the surface defect.

[0003] In some embodiments, the laser apparatus is structured to receive parameters of the laser, wherein the parameters of the laser are at least one selected from the group consisting of: a joined object distance, a joined object material, a laser power, a scan speed, a pulse frequency, a spot variable, a repetition, and a cycle time.

[0004] In another aspect, a method for laser retexturing a joined object is presented. The method may include providing a joiner for joining a first object with a second object into the joined object, and providing a laser apparatus for receiving the joined object, wherein the laser apparatus may include a laser, and wherein the laser is structured to texture a surface of the joined object comprising the surface defect.

[0005] In yet another aspect, a method for laser retexturing a joined object is presented. The method may include receiving a first object and a second object at a joiner, joining the first object with the second object to form a joined object, wherein the joined object may include a surface defect, providing the joined object to a laser apparatus, and subjecting a surface that may include the surface defect of the joined object to the laser, wherein the laser applies a texture to the surface.

[0006] In some embodiments, providing the joined object to the laser apparatus may include defining parameters of a laser of the laser apparatus, wherein the parameters of the laser are at least one selected from the group consisting of: a joined object distance, a joined object material, a laser power, a scan speed, a pulse frequency, a spot variable, a repetition, and a cycle time.

[0007] BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Having thus described embodiments of the invention in general terms, reference will now be made to the accompanying drawings, wherein:

[0009] Figure 1 illustrates a flow diagram for laser retexturing, according to one embodiment of the present invention;

[0010] Figure 2A illustrates a perspective view of an apparatus for joining objects, according to one embodiment of the present invention;

[0011] Figure 2B illustrates a perspective view of an apparatus for laser retexturing, according to one embodiment of the present invention;

[0012] Figure 3 A illustrates a perspective view of an object before and after laser retexturing, according to one embodiment of the present invention; and

[0013] Figure 3B illustrates a perspective view of an object before and after laser retexturing, according to one embodiment of the present invention.DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

[0014] Embodiments of the present invention now may be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure may satisfy applicable legal requirements. Like numbers refer to like elements throughout. Where possible, any terms expressed in the singular form herein are meant to also include the plural form and vice versa, unless explicitly stated otherwise. Also, as used herein, the term “a” and / or “an” shall mean “one or more,” even though the phrase “one or more” is also used herein. Furthermore, when it is said herein that something is “based on” something else, it may be based on one or more other things as well. In other words, unless expressly indicated otherwise, as used herein “based on” means “based at least in part on” or “based at least partially on.”

[0015] Additionally, certain terminology is used herein for convenience only and is not to be interpreted as a limitation on the embodiments described. For example, the words “top,” “bottom,” “upper,” “lower,” “left,” “right,” “horizontal,” “vertical,” “upward,” and “downward” merely describe the configurations as depicted in the figures. Indeed, the referenced components in the figures may be oriented in any direction, unless specified otherwise, the configurative terminology used herein should be understood as encompassing such variations.

[0016] It should also be understood that “operable communication” or “operably coupled” as used herein, means that the components may be formed integrally with each other, or may be formed separately and coupled together. Furthermore, “operable communication” means that the components may be formed directly to each other, or to each other with one or more components located between the components that are operatively coupled together. Furthermore, “operable communication” or “operable coupled” may mean that the components are detachable from each other, or that they are permanently coupled together. Furthermore, components in operablecommunication may mean that the components retain at least some freedom of movement in one or more directions or may be rotated about an axis (i.e., rotationally coupled, pivotally coupled). Furthermore, “operable communication” or “operably coupled” may mean that components may be electronically connected and / or in fluid communication with one another.

[0017] Embodiments of the invention are directed to an apparatus for laser retexturing and a method of use. The apparatus and method described herein allows for the application of a texturized surface to an object formed from two separate objects, where the joining process between the two processes has caused surface defects or deformations. The apparatus described herein includes a laser apparatus, where the laser of the laser apparatus alters the surface properties of the surface(s) containing the defects or deformations. By supplying the laser apparatus with the appropriate parameters, the laser generates heat at predefined portions of the surface to texturize the surface in a manner that closely matches the surrounding surfaces untreated by the laser.

[0018] The technical features of the apparatus and method described herein provide a novel approach to the retexturing of surfaces of joined parts, such that design and fabrication of joined objects can be centered around improving the strength of the final product, with the ability to improve the aesthetics after achieving a strong joining of the objects. By utilizing lasers, the apparatus allows for control of the retexturing process, enabling the creation of textures or surface modifications of the joined objects. This approach allows for enhancing the visual uniformity, functional properties, and overall quality of the finished objects. Furthermore, the flexibility of the method enables adaptability to different materials and design requirements, making it suitable for a wide range of applications.

[0019] Importantly, the apparatus improves upon the traditional mechanical postprocessing and re-texturing techniques by reducing the amount of time required to retexture surfaces of joined objects, improving the consistency of the texture applied, increasing the flexibility in the re-retexturing to adapt to various materials, and achieving a higher level of precision in the retexturing process. Traditional mechanical retexturing processes such as polishing, grinding, sanding, and sandblasting rely on mechanical abrasion and removal of material to achieve the desired texture. However, these methods often lead to inconsistencies, irregularities, and variations in texture application. Additionally, they can be time-consuming, labor-intensive, and may cause unintended damage to the underlying structure of the objects.

[0020] By utilizing a laser apparatus for the retexturing of joined objects, joined objects with surface defects and texture irregularities are able to be retextured more quickly and consistently, with a reduced cycle time, less human involvement, and higher precision. Furthermore, by eliminating the need for mechanical retexturing, rejoined objects are more likely to retain structural integrity and be dimensionally accurate. The elimination of mechanical retexturing processes reduces the risk of introducing structural weaknesses or deformations to the rejoined objects. By relying on non-contact and non-intrusive techniques, the apparatus ensures that the dimensional accuracy and structural integrity of the rejoined objects are maintained throughout the retexturing process.

[0021] While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of, and not restrictive on, the broad invention, and that this invention not be limited to the specific constructions and arrangements shown and described, since various other changes, combinations, omissions, modifications and substitutions, in addition to those set forth in the above paragraphs, are possible. Those skilled in the art will appreciate that various adaptations and modifications of the just described embodiments can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.

[0022] As will be appreciated by one of ordinary skill in the art in view of this disclosure, the present invention may include and / or be embodied as an apparatus (including, for example, a system, machine, device, computer program product, and / or the like), as a method (including, for example, a computer-implemented process, and / or the like), or as any combination of the foregoing. Accordingly, embodiments of the present invention may take the form of an entirely apparatus embodiment, an entirely software embodiment (including firmware, resident software, micro-code, stored procedures in a database, or the like), an entirely hardware embodiment, or an embodiment combining the apparatus, software, and hardware aspects that may generally be referred to herein as a “system.” Furthermore, embodiments of the present invention may take the form of a computer program product that includes a computer-readable storage medium having one or more computer-executable program code portions stored therein. As used herein, a processor, which may include one or more processors, may be “structured to” or “configured to” perform a certain function in a variety of ways, including, for example, by having one or moregeneral -purpose circuits perform the function by executing one or more computer-executable program code portions embodied in a computer-readable medium, and / or by having one or more application-specific circuits perform the function.

[0023] It will be understood that any suitable computer-readable medium may be utilized to store computer-executable program code for performing the method(s) described herein. The computer-readable medium may include, but is not limited to, a non-transitory computer-readable medium, such as a tangible electronic, magnetic, optical, electromagnetic, infrared, and / or semiconductor system, device, and / or other apparatus. For example, in some embodiments, the non-transitory computer-readable medium includes a tangible medium such as a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), a compact disc read-only memory (CD-ROM), and / or some other tangible optical and / or magnetic storage device. In other embodiments of the present invention, however, the computer-readable medium may be transitory, such as, for example, a propagation signal including computer-executable program code portions embodied therein.

[0024] One or more computer-executable program code portions (e.g., computer instructions) for carrying out operations of the present invention may include object-oriented, scripted, and / or unscripted programming languages, such as, for example, Java, Perl, Smalltalk, C++, SAS, SQL, Python, Objective C, JavaScript, and / or the like. In some embodiments, the one or more computer-executable program code portions for carrying out operations of embodiments of the present invention are written in conventional procedural programming languages, such as the “C” programming languages and / or similar programming languages. The computer program code may alternatively or additionally be written in one or more multi-paradigm programming languages, such as, for example, F#.

[0025] The one or more computer-executable program code portions may be stored in a transitory and / or non-transitory computer-readable medium (e.g. a memory) that can direct, instruct, and / or cause a computer and / or other programmable data processing apparatus to function in a particular manner, such that the computer-executable program code portions stored in the computer-readable medium produce an article of manufacture including instruction mechanisms which implement the steps and / or functions specified in the flowchart(s) and / or block diagram block(s). The one or more computer-executable program code portions may also be loaded ontoa computer, controller, and / or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer and / or other programmable apparatus. In some embodiments, this produces a computer-implemented process such that the one or more computerexecutable program code portions which execute on the computer and / or other programmable apparatus provide operational steps to implement the steps specified in the flowchart(s) and / or the functions specified in the block diagram block(s). Alternatively, computer-implemented steps may be combined with, and / or replaced with, operator- and / or human-implemented steps in order to carry out an embodiment of the present invention.

[0026] Figure 1 illustrates a flow diagram for laser retexturing, according to one embodiment of the present invention. At block 102, a joiner 202 receives a first object and a second object. The apparatus for joining objects, or “joiner” 202 as it may be referred to throughout this disclosure, may take numerous forms.

[0027] Turning briefly to Figure 2A, Figure 2A illustrates a perspective view of an apparatus for joining objects, according to one embodiment of the present invention. The joiner 202 as shown in Figure 2A is an ultrasonic welder, which functions by receiving a first object and a second object, and applying high-frequency (ultrasonic) mechanical vibrations to create friction and heat at the interface between the first and second objects. This localized heating causes the materials to meld together and form a strong bond. The ultrasonic welder typically consists of a transducer that converts electrical energy into mechanical vibrations, and a horn 206 that transmits these vibrations to the joint area between the first and second objects. When the first and second objects are brought into contact in a receiving jig 204, pressure is applied by the horn 206, and the ultrasonic vibrations are applied by the horn 206 to the interface. These vibrations create interlocking at the joining interface.

[0028] Although the joiner 202 depicted graphically in Figure 2A is an ultrasonic welder, it shall be appreciated that other joiners may be used in the apparatus and throughout the process described, including, but not limited to, laser welders, friction stir welders, overmolding machines, and adhesive bonding devices. The choice of joiner 202 depends on various factors such as the materials being joined, the desired strength of the bond, production throughput (i.e., cycle time), and costs. For example, laser welders, offer precise joining capabilities suitable for intricate assemblies. Friction stir welders are well-suited for joining materials with different melting points. Adhesive bonding techniques provide additional flexibility.

[0029] Regardless of the specific type of joining technology used in joiner 202, it shall be appreciated that when heat is generated and applied to one or more objects for purposes of joining the objects, the same melting point of the material of the one or more objects that allows for such joining may also distort, warp, alter the surface texture characteristics due to the application of the heat. Thus, these surface defects are apparent in the joined object, leading to an aesthetically inconsistent joined object.

[0030] Returning now to Figure 1, at block 104, the joiner 202 joins the first object with the second object to form a joined object, wherein the joined object comprises a surface defect. Thereafter, at block 106, the joined object is provided to a laser apparatus 208.

[0031] Briefly turning to Figure 2B, Figure 2B illustrates a perspective view of an apparatus for laser retexturing, according to one embodiment of the present invention. The laser apparatus 208 includes a platform 210 for receiving the joined object, and a laser generator 212 for applying laser energy to the joined object. Specifically, the joined object with surfaced defects is received by the laser apparatus 208 on the platform 210, which in some embodiments may include a retainer for securing the joined object to prevent unwanted movement.

[0032] Although the laser apparatus is depicted in Figure 2B as an independent device separate from the joiner 202, in some embodiments the laser apparatus 208 and the joiner 202 are operatively coupled to each other, through automation equipment configured to remove the joined object from the joiner 202 and place on the platform 210 of the laser apparatus 208. Such automation equipment may include a robotic arm, conveyor belt(s), or a combination thereof.

[0033] Returning now to Figure 1, at block 108, parameters of the laser of the laser apparatus 208 are defined. The parameters are at least one selected from the group consisting of: a joined object distance, a joined object material, a laser power, a scan speed, a pulse frequency, a spot variable, a repetition, and a cycle time.

[0034] Operatively coupled to the laser apparatus 208 may be a control unit with a control interface, where the control unit directs the positioning and / or angle of the laser and various other parameters. Accordingly, these parameters may be input into the control interface of the control unit prior to the retexturing of the joined object. The parameters may be predetermined based on characteristics of the joined object, including the material type, size, opacity, desired texture, and the degree to which a surface of the joined object has defects.

[0035] Specifically, parameters may be predetermined such as a joined object distance (specified as a distance in millimeters or inches), a joined object material (such as high density polyethylene, polycarbonate, acetal, and so forth), a laser power (specified as a percentage from 0% to 100%), a scan speed (specified as a velocity, such as 1000 mm per second), a pulse frequency (specified as a frequency, such as 50 kHz), a spot variable (specified as a whole number, such as (-)40, to indicate the laser size and / or focus parameters), a repetition (specified as a whole number, to indicate if the laser retexturing is to be repeated), and a cycle time (specified as a number of seconds over which the laser retexturing is to occur).

[0036] Moreover, in some embodiments, the parameters regarding the path of the laser are predetermined at the control interface of the control unit. These predetermined parameters provide a means for users to establish specific paths for the laser beam without requiring manual adjustments during operation. By inputting the desired coordinates or utilizing preprogrammed templates, a user defines the trajectory of the laser, often determined and selected on a three- dimensional representation of the joined object displayed on the control interface. For example, in some embodiments, a user may select the path of the laser to only retexture one of several surfaces of a joined object, with the surface selected containing surface defects. In other embodiments, a user may elect the path of the laser to resurface the entire joined object reachable by the laser at a given position of the joined object relative the laser.

[0037] Returning now to Figure 1, at block 110, the surface of the joined object comprising the surface defect is subjected to the laser of the laser apparatus 208. Once the joined object is positioned at the platform 210, a control signal initiates a laser to be emitted from the laser generator 212 of the laser apparatus 208. The laser is structured to texture a surface of the joined object. One or more lasers may be emitted by the laser generator 212, such as a C02 laser, fiber laser, YV04, Nd: YAG laser, Excimer laser, disk laser, diode laser, UV laser, hybrid lasers, and so forth. In the embodiment depicted in Figure 2B, a laser structured for marking objects is implemented. In any embodiments, the laser applies a texture to the surface by removing or displacing material as a result of the laser energy directed to the surface of the joined object according to the predetermined parameters.

[0038] Figure 3A illustrates a perspective view of an object before and after laser retexturing, according to one embodiment of the present invention. As illustrated in Figure 3A, the joined object 214 includes a surface 216a comprising surface defects. After being subjectedto the apparatus described in Figures 2A and 2B (and the method described herein with respect to Figure 1), the surface 216b, which corresponds to the surface 216a prior to laser retexturing, contains no surface defects. Moreover, surface 216b of the joined object 214 is uniform in appearance and texture with other portions of the joined object 214.

[0039] Similarly, Figure 3B illustrates a perspective view of another object before and after laser retexturing, according to one embodiment of the present invention. As illustrated in Figure 2B, the joined object 218 includes a surface 224a comprising two localized portions 220a, 222a, comprising surface defects. After being subjected to the apparatus described in Figures 2A and 2B (and the method described herein with respect to Figure 1), the surface 224b, which corresponds to the surface 224a prior to laser retexturing, contains no surface defects, such that the two corresponding localized portions 220b, 222b are uniform in appearance and texture with the remainder of the surface 224b. As described previously, in some embodiments this uniformity may be the result of applying the laser to the entirety of the surface 224a. However, in other embodiments, this uniformity may be the result of only applying the laser to localized portions 220a and 222a.

[0040] It shall be appreciated that numerous types of textures with varying gloss levels and roughness can be applied to the joined object by the laser apparatus 208, targeting various engineering standards for surface finish designations. For instance, options include a Ra value (arithmetic average of profile height deviations from the mean line) of 0.2 pm, providing a smooth surface. Alternatively, a Ra value of 1.6 pm may be selected for a matte texture. If a more rugged aesthetic is desired, a Ra value of 3.2 pm may be selected.

[0041] Although many embodiments of the present invention have just been described above, the present invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Also, it will be understood that, where possible, any of the advantages, features, functions, devices, and / or operational aspects of any of the embodiments of the present invention described and / or contemplated herein may be included in any of the other embodiments of the present invention described and / or contemplated herein, and / or vice versa. In addition, where possible, any terms expressed in the singular form herein are meant to also include the plural form and / or vice versa, unless explicitly stated otherwise.Accordingly, the terms “a” and / or “an” shall mean “one or more,” even though the phrase “one or more” is also used herein. Like numbers refer to like elements throughout.

[0042] While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that this invention not be limited to the specific constructions and arrangements shown and described, since various other changes, combinations, omissions, modifications and substitutions, in addition to those set forth in the above paragraphs, are possible. Those skilled in the art will appreciate that various adaptations, modifications, and combinations of the just described embodiments can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.

Claims

WHAT IS CLAIMED IS:

1. An apparatus for laser retexturing of a joined object, the apparatus comprising: a joiner for joining a first object with a second object into the joined object, wherein the joined object comprises a surface defect; and a laser apparatus for receiving the joined object, wherein the laser apparatus comprises a laser, and wherein the laser is structured to texture a surface of the joined object comprising the surface defect.

2. The apparatus of claim 1, wherein the laser apparatus is structured to receive parameters of the laser, wherein the parameters of the laser are at least one selected from the group consisting of: a joined object distance, a joined object material, a laser power, a scan speed, a pulse frequency, a spot variable, a repetition, and a cycle time.

3. A method for laser retexturing a joined object, the method comprising: providing a joiner for joining a first object with a second object into the joined object; and providing a laser apparatus for receiving the joined object, wherein the laser apparatus comprises a laser, and wherein the laser is structured to texture a surface of the joined object comprising the surface defect.

4. A method for laser retexturing testing of an article in a testing device, the method comprising: receiving a first object and a second object at a joiner; joining the first object with the second object to form a joined object, wherein the joined object comprises a surface defect; providing the joined object to a laser apparatus; and subjecting a surface comprising the surface defect of the joined object to the laser, wherein the laser applies a texture to the surface.

5. The method of claim 4, wherein providing the joined object to the laser apparatus comprises: defining parameters of a laser of the laser apparatus, wherein the parameters of the laser are at least one selected from the group consisting of: a joined object distance, a joined object material, a laser power, a scan speed, a pulse frequency, a spot variable, a repetition, and a cycle time.

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