Laser Boring With Mechanical Core Removal for Hard Rock
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Solution Overview
Problem
Existing boring machines, such as tunnel and auger boring machines, face high upfront costs, limited length, and inefficiency in drilling hard materials like rocks and minerals, with frequent breakdowns and limited effectiveness.
Innovation Solution
A method combining a laser beam to liquefy or gasify earth, forming a channel and cut portion, and using a sleeve to detach and remove sections, allowing for efficient bore creation by fracturing ligaments and minimizing material accumulation on sidewalls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If tunnel boring machines are used to bore tunnels, then the machine can cut through earth and remove excavated material, but the upfront costs are high and the active cutting time is limited to about 50% due to breakdowns and head changes
Solution Approach 1:
The patent replaces the mechanical cutting system of traditional tunnel boring machines with a laser-based system. The laser beam melts and vaporizes rock material without mechanical contact, eliminating wear on cutting tools and reducing breakdowns. The laser system can operate continuously without the need for head changes or blade replacements, thereby increasing active cutting time beyond the 50% limitation of mechanical systems.
2Length of moving object
If auger boring machines are used to bore smaller tubular holes, then the machine can cut and remove earth simultaneously, but the machine is limited in length to less than about 100 m and is less effective for drilling hard materials
Solution Approach 1:
The patent replaces the mechanical auger cutting system with a laser-based melting and vaporization system. The high-energy laser beam can penetrate and process hard materials such as rocks and minerals that are resistant to mechanical auger cutting. This enables drilling of much longer bores beyond the 100 m limitation, as the laser system does not suffer from the same mechanical constraints and can maintain cutting effectiveness over extended distances and through harder formations.
3Productivity
If a laser beam is used to liquefy and gasify target material, then the channel can be removed efficiently, but material may accumulate on the sidewalls of the channel
Solution Approach 1:
The patent employs a secondary laser beam that periodically or continuously scans the sidewalls of the channel to vaporize and remove accumulated material. This periodic cleaning action prevents significant material buildup that would otherwise reduce channel capacity and require additional removal steps. The secondary laser beam operates in coordination with the primary channel-forming laser, maintaining channel efficiency throughout the drilling process.
4Manufacturing precision
If a closed loop laser path is used to define a cut portion, then a bore can be formed by removing the cut portion, but a ligament remains attached to the target requiring additional separation steps
Solution Approach 1:
The patent extracts or removes the ligament material that connects the cut portion to the target using the laser beam. After the closed-loop laser path defines the bore geometry with high precision, the laser subsequently targets and vaporizes the remaining ligament, completely separating the cut portion from the target. This eliminates the need for additional mechanical separation steps and achieves complete bore formation in a unified laser processing sequence.
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 approach reduces costs and extends drilling capabilities by enabling longer bores in hard materials with reduced downtime and increased efficiency through the use of directed laser energy and mechanical detachment methods.
Implementation Method 1
directing a laser beam at an exposed face of a bulk target in a longitudinal direction, where the laser beam can be configured to liquefy and/or gasify the target within the laser beam
Implementation Method 2
the laser beam can be configured to liquefy and/or gasify the target within the laser beam
Implementation Method 3
the laser beam can be configured to liquefy and/or gasify the target within the laser beam
Implementation Method 4
cooling the sleeve while inserted within the closed loop, thereby causing the sleeve to contract into contact with at least a portion of the lateral outer surface of the cut portion
Data Source
AI summary
A boring method is provided and can include directing a laser beam at an exposed face of a bulk target in a longitudinal direction. The laser beam can be configured to liquefy and/or gasify the target within the laser beam. The method can also include removing, by the laser beam, a channel of predetermined length and width within the target. The method can further include moving the laser beam in a closed loop of predetermined diameter to define a cut portion of the target laterally bounded by the closed loop. A ligament of the cut portion can remain attached to the target. The method can additionally include separating the ligament from the target. The method can also include removing the cut portion from the target after separating the ligament to form a bore.