Laser Ablation of Coated Abrasive Articles
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Solution Overview
Problem
Infrared laser ablating of coated abrasive articles often results in excessive heat generation, leading to edge contamination, scratches, and reduced performance due to hardened residues and adhesive issues, particularly when using CO2 lasers at a single wavelength of 10.6 micrometers.
Innovation Solution
Using infrared laser beams with wavelengths matched to the absorption profiles of the materials in the coated abrasive articles, specifically employing multiple laser beams with different wavelengths to ablate various components, and optimizing beam power and intensity to reduce heat generation and improve processing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If CO2 laser at 10.6 micrometers is used for ablation, then processing efficiency is improved, but excessive heat generation occurs causing edge contamination and adhesive residue
Solution Approach 1:
The patent changes the laser wavelength parameter from the conventional 10.6 micrometers to alternative wavelengths (9.3-9.6 micrometers or 10.28-10.3 micrometers) that better match the absorption profiles of the abrasive particles and binder materials. This parameter optimization enables efficient ablation while reducing excessive heat generation and associated harmful effects like adhesive residue and edge contamination.
Solution Approach 2:
The patent employs dynamic adjustment of laser parameters including wavelength selection based on material absorption characteristics, pulse duration optimization, and beam intensity modulation. These dynamic adjustments allow the laser processing to adapt to different material compositions and thicknesses, achieving clean ablation with minimal heat-affected zones.
2Temperature
If laser wavelength is tuned away from 10.6 micrometers, then heat generation is reduced, but average output power of the laser declines
Solution Approach 1:
The patent identifies and utilizes alternative wavelength regions (9.3-9.6 micrometers and 10.28-10.3 micrometers) where laser sources can maintain high average output power while matching the absorption characteristics of abrasive materials. This parameter optimization balances both power output and heat generation control.
Solution Approach 2:
The patent replaces the conventional single-wavelength CO2 laser system with alternative laser sources or tunable laser systems that can operate at optimized wavelengths. This substitution enables maintaining high processing power while reducing thermal damage through better absorption matching.
3Productivity
If high beam intensity is used to increase ablation rate, then processing speed is improved, but heat-induced damage and hardened edges increase
Solution Approach 1:
The patent employs pulsed laser operation with optimized pulse durations and repetition rates. This periodic action allows material to cool between pulses, reducing heat accumulation and hardened edge formation while maintaining high overall ablation rates through cumulative material removal.
Solution Approach 2:
The patent optimizes the relationship between beam intensity, pulse duration, and wavelength to achieve clean ablation. By adjusting these parameters to match material absorption characteristics, the process achieves high removal rates without excessive heat generation, preventing manufacturing defects.
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 method effectively reduces adhesive residue and scratches, maintaining the performance of coated abrasive articles by minimizing heat-induced damage and optimizing the ablation process, resulting in cleaner cuts and reduced adverse edge effects.
Implementation Method 1
infrared laser-induced ablation
Implementation Method 2
absorption profile of the material in the coated abrasive to be ablated
Implementation Method 3
laser wavelength that is appropriately matched to the absorption profile of the material
Data Source
Figure 1~2
Figure 3A~3B
Figure 4A~4B
AI summary
A coated abrasive article comprises an abrasive layer secured to a backing. The abrasive layer comprises abrasive particles secured by at least one binder to a first major surface of the backing. A supersize is disposed on at least a portion of the abrasive layer. The coated abrasive article has a melt flow zone adjacent to an edge of the coated abrasive article, wherein the melt flow zone has a maximum width of less than 100 micrometers, and the melt flow zone has a maximum height of less than 40 micrometers. Methods of using infrared lasers to ablate coated abrasive articles are also disclosed, wherein a laser wavelength is matched to a component of the coated abrasive article.