Infrared Laser Structuring of Etch-Resistant Coatings on Press Tools
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Solution Overview
Problem
Conventional methods for producing etch-resistant structures on metallic press tools, such as endless press belts and press plates, face issues with precision, edge quality, and environmental concerns, including ink runoff, incomplete masking, and labor-intensive photochemical processes, which result in unsalable structures with visible edges and reduced economic viability.
Innovation Solution
The use of a laser emitting in the infrared range, specifically CO2 lasers or YAG lasers, to burn out an etch-resistant coating on press tools, minimizing heat dissipation and maintaining the metallic surface properties, allowing for precise structure creation with sharp contours and reduced edge effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional printing methods are used to apply masks, then the masking process can be completed, but the mask edges become blurred and printing ink runs off, resulting in poor manufacturing precision
Solution Approach 1:
The patent replaces the mechanical printing roller system with a laser-based system. Instead of using physical contact between a printing roller and the press tool surface, the invention uses laser radiation to directly烧蚀 the etch-resistant coating, thereby eliminating mechanical printing defects such as ink runoff and blurred edges while achieving sharp mask contours
Solution Approach 2:
The patent changes the physical parameter of the laser wavelength to infrared range (780 nm to 1 mm), which is optimally absorbed by the etch-resistant coating. This parameter selection enables precise energy coupling to the coating material, allowing clean烧蚀 with sharp edges while minimizing heat diffusion to the underlying metallic surface
2Manufacturing precision
If photochemical processes are used to create masks, then masks can be formed, but the process becomes labor-intensive and environmentally harmful
Solution Approach 1:
The patent extracts and eliminates the photochemical processing steps (photoresist application, exposure, development, washing) from the mask creation process. By using laser烧蚀 directly on the etch-resistant coating, the invention removes the complex photochemical workflow and its associated environmental hazards, while still achieving precise mask formation
Solution Approach 2:
The patent replaces the photochemical system with a direct laser-based烧蚀 system. Instead of using photoresist chemicals and exposure equipment, the invention uses controlled laser radiation to directly remove the coating where masks are needed, significantly simplifying the process and eliminating chemical waste
3Productivity
If high energy density is used in laser processing, then coating can be removed efficiently, but heat dissipation damages the metallic surface
Solution Approach 1:
The patent optimizes the laser wavelength parameter to the infrared range (780 nm to 1 mm), which is optimally absorbed by the etch-resistant coating but poorly coupled into the metallic substrate. This parameter selection enables efficient coating removal through selective absorption, while the reflected energy prevents excessive heat accumulation and damage to the underlying metal surface
Solution Approach 2:
The patent employs pulsed laser operation mode, delivering energy in periodic pulses rather than continuous wave. This periodic action allows brief intervals between pulses for heat dissipation, preventing thermal accumulation and damage to the metallic surface while still achieving efficient coating removal through repeated pulsed烧蚀 cycles
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method achieves precise, edge-sharp etch-resistant structures on large-format press tools with improved surface quality and reduced environmental impact, enhancing the economic and technical feasibility of the process.
Implementation Method 1
the laser structures from the etch-resistant coating burns out
Implementation Method 2
a laser which emits with a wavelength in the infrared range between 780 nm and 1 mm surprisingly avoids edge effects on the processed press tool if the coating is burned out with the laser
Implementation Method 3
a laser which emits with a wavelength in the infrared range between 780 nm and 1 mm surprisingly avoids edge effects on the processed press tool
Implementation Method 4
minimizing heat dissipation and maintaining the metallic surface properties
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a method for producing etch-resistant structures(masks)on the surfaces of metallic pressing tools, specifically continuous press bands or press plates, by means of a laser, wherein a surface of the press tool to be structured is provided with a thermally-sensitive, etch-resistant coating and the laser burns structures out of the etch-resistant coating. In order to prevent negative influences when lasering on the surface of the press plate, the invention proposes that the structure is burned with a laser that emits light having a wavelength in the infrared range between 780 nm and 1 mm.