Laser Ablation Cleaning for Composite Molds with Protective Optical Layers

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Traditional cleaning methods for processing tools, such as molds used for forming composite parts, are time-consuming, pose ergonomic concerns, and can damage the tools or require hazardous chemicals, while existing techniques like media blasting and chemical cleaning have limitations and safety issues.

Innovation Solution

The use of laser ablation with a protective optical layer on non-metal base portions of processing tools, which reflects or absorbs the laser beam to remove residue without damaging the tool, and includes a release layer that can be retained or removed during cleaning, with feedback from emitted light used to control the laser orientation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional cleaning methods (media blasting, sanding, chemical cleaning) are used, then residue can be removed from processing tools, but the tools may be damaged, consumables are required, and ergonomic concerns arise

Engineering Contradiction:

Improvetool integrityVSAvoidergonomic concerns

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent replaces mechanical cleaning methods (media blasting, sanding) with laser ablation technology. The laser beam removes residue through photothermal and photomechanical effects without requiring physical contact or consumables, thereby preserving tool integrity while eliminating ergonomic concerns associated with manual abrasive techniques

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a protective optical layer as an intermediary between the laser beam and the processing tool base portion. This layer absorbs or reflects laser energy to protect the tool during cleaning operations, enabling effective residue removal while maintaining tool integrity

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If laser ablation is used to clean processing tools, then cleaning speed and effectiveness improve, but the tool may be damaged due to laser energy absorption

Engineering Contradiction:

Improvecleaning speedVSAvoidlaser damage to tool

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The protective optical layer serves as a mediator that intercepts laser energy before it reaches the processing tool base portion. The layer is specifically designed to absorb or reflect laser wavelengths, enabling high-speed cleaning while preventing thermal damage to the tool substrate

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent modifies the optical parameters of the tool surface by applying a protective layer with specific optical properties (absorption coefficient, reflectivity) tailored to the laser wavelength used. This parameter change enables selective energy absorption at the surface while protecting the underlying tool material

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If composite molds with release coatings are used, then the molds can form composite parts, but the release coatings may be damaged by laser ablation

Engineering Contradiction:

Improvemold functionalityVSAvoidrelease coating integrity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The protective optical layer acts as a dedicated intermediary that absorbs laser energy in preference to the release coating and base material. This layered structure allows the release coating to maintain its release functionality while the protective layer shields both the coating and base material from laser-induced damage

Inventive Principle:

Principle #24Intermediary (Mediator)

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 effectively removes residue from processing tools without damaging the tool, addresses ergonomic and safety concerns, and enhances processing speed and quality by using laser ablation with a protective optical layer that shields the tool from laser damage.

Implementation Method 1

The protective optical layer reflects or absorbs the laser beam to prevent the laser energy from reaching and damaging the non-metal base portion

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 2

The protective optical layer reflects or absorbs the laser beam

Methodology Applied

Scientific EffectAbsorption (EM radiation): Absorption (EM radiation)

Implementation Method 3

exposing the surface to the laser beam ablates the residue away from the surface

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 4

laser ablation

Methodology Applied

Scientific EffectAblation: Ablation

Data Source

PatentUS10702895B2Processing tool cleaning using laser ablation

Publication Date: 2020.07.07 THE BOEING CO

AI summary

Provided are molds, comprising non-metal base portions and protective optical layers that cover and shield these base portions from laser ablation. For example, a protective optical layer may reflect a laser beam used for ablating the mold. Methods of forming these protective optical layers on non-metal base portions are also provided. In some embodiments, this protective optical layer is the outermost layer exposed to the environment. Alternatively, the protective optical layer may be covered by a release layer. The release layer may be retained or removed during laser ablation. In some embodiments, light emitted by a mold during laser ablation is analyzed to determine performance of its protective optical layer. This feedback may be used to control the laser ablation such as to control orientation of the laser beam relative to the mold.