Coated Metal Grate Support for Cleaner Laser Cutting
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Solution Overview
Problem
In laser cutting machines, molten and re-solidified workpiece material tends to stick to the support, leading to uneven support surfaces, inaccurate cutting, and frequent cleaning or replacement needs, due to the self-enhancing effect of material accumulation and welding or soldering of cut parts to the support.
Innovation Solution
A laser cutting machine with a workpiece support featuring a metallic grate coated with a non-metallic, anti-adhesive coating, which reduces the adhesion of metallic workpieces at temperatures below and above their melting point, preventing material sticking and allowing for easy regeneration of the grate by mechanical removal and reapplication of the coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metallic grate is used as workpiece support, then the support provides structural strength and heat resistance, but molten workpiece material sticks to the grate surface causing material accumulation and support degradation
Solution Approach 1:
The patent applies a non-metallic coating (such as ceramic, glass, or polymer-based material) onto the metallic grate surface, creating a composite structure that combines the structural strength of metal with the anti-adhesive properties of non-metallic materials. This composite approach allows the support to maintain high mechanical strength while preventing molten material from sticking to the surface.
Solution Approach 2:
The non-metallic coating acts as an intermediary layer between the metallic grate and the molten workpiece material. This intermediate layer prevents direct contact and adhesion between the metal surface and the molten material, thereby eliminating the sticking problem while allowing the metallic grate to provide its structural function.
2Manufacturing precision
If molten material sticks to the support, then material accumulation occurs leading to uneven support surfaces, but frequent cleaning or replacement is required reducing productivity
Solution Approach 1:
The non-metallic coating provides self-release properties where molten material does not adhere to the support surface. Cut-out parts and small rest pieces automatically detach and fall away after cutting, eliminating the need for manual cleaning interventions and maintaining continuous productivity.
Solution Approach 2:
Instead of requiring frequent replacement of the entire metallic grate, the patent enables regeneration by removing and reapplying the non-metallic coating. This approach is more economical than replacing the whole support structure and maintains productivity by extending the service life of the grate through coating renewal.
3Strength
If cut parts are welded or soldered to the support by molten material, then removal of cut parts becomes difficult, but automated feeding of new workpieces is interfered with
Solution Approach 1:
The non-metallic coating serves as an intermediary barrier that prevents molten material from creating weld or solder bonds between the workpiece support and cut parts. This intermediary layer ensures that cut parts remain detached and can be easily removed, allowing automated feeding systems to operate without interference.
Solution Approach 2:
The patent replaces the metallic bonding mechanism (welding/soldering) with a non-adhesive surface property. Instead of allowing metallurgical bonds to form between the support and cut parts, the non-metallic coating creates a surface where no such bonds can establish, ensuring easy separation and continuous automated operation.
4Stability of the object's composition
If the grate elements grow by material sticking, then the support shape becomes undefined, but the anti-adhesive coating prevents this growth
Solution Approach 1:
The metallic grate combined with non-metallic coating creates a composite structure where the coating layer protects the metallic substrate from material accumulation. This composite design maintains the original grate shape and dimensions by preventing the self-enhancing growth effect that occurs with uncoated metallic surfaces.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The anti-adhesive coating significantly reduces the sticking of molten metal to the grate, preventing uneven support and material accumulation, enhancing the longevity of the grate and improving cutting accuracy by ensuring a clean and even surface for subsequent cuts.
Implementation Method 1
At least a support portion of a surface of the metallic grate, namely especially an array of support spots, is coated by a non-metallic coating. The coating serves as an anti-adhesive (anti-adherent) coating and has according properties, i.e. the coating is equipped to have anti-adhesive properties for metallic workpieces.
Data Source
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AI summary
The laser cutting machine in addition to a laser cutting head and a laser source comprises a workpiece support (200), the workpiece support comprising a metallic grate. At least a part, namely a support portion, of a surface of the metallic grate is coated by a for example non-metallic coating. Examples of such surface coatings include ceramic coatings.