Laser Treatment Surface Analysis for Composite Adhesion

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Solution Overview

Problem

Current methods for inspecting composite material surfaces, particularly those treated with lasers, rely on qualitative and often manual processes, which are laborious and lack precision, making it difficult to assess the level of surface treatment and predict coating adhesion effectively.

Innovation Solution

A method and system utilizing surface analysis techniques such as gloss analysis, Fourier transform infrared spectroscopy, color analysis, contact angle analysis, surface resistivity, optical interferometry, and optically stimulated electron emission to quantify the level of laser treatment on carbon-containing composite material surfaces, allowing for the prediction of coating adhesion and material removal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If automated laser treatment is used to condition composite material surfaces, then productivity and consistency are improved, but measurement and verification of treatment quality become more difficult

Engineering Contradiction:

Improvesurface treatment efficiencyVSAvoidsurface treatment quality assessment

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent applies optical detection methods that measure changes in surface optical properties (reflectivity, absorption, color) resulting from laser treatment. Different treatment levels produce distinct optical signatures that can be quantified and correlated to treatment quality, enabling precise measurement of automated laser treatment effects.

Inventive Principle:

Principle #32Color changes

Solution Approach 2:

The patent replaces manual mechanical inspection methods with automated optical measurement systems. Sensors and imaging systems detect surface treatment characteristics non-contactively, substituting human visual inspection and tactile methods with automated optical detection that provides more precise and consistent measurements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If manual surface inspection methods are used to verify laser treatment, then measurement capability is maintained, but labor intensity and time consumption increase

Engineering Contradiction:

Improvesurface inspection accuracyVSAvoidinspection time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent enables continuous inspection by integrating optical sensors that can rapidly scan and analyze multiple surfaces without interruption. The automated optical system maintains continuous measurement capability, eliminating the discontinuous nature of manual inspection where each surface must be individually examined by hand.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The optical measurement system performs self-calibration and automatic analysis of surface treatment quality. The system independently captures optical data, processes images, compares measurements against acceptance criteria, and generates inspection results without requiring manual intervention for each measurement step.

Inventive Principle:

Principle #25Self-service

3Device complexity

If qualitative manual inspection is used for surface preparation verification, then simplicity is maintained, but manufacturing precision and adhesion prediction capability deteriorate

Engineering Contradiction:

Improveinspection system simplicityVSAvoidsurface preparation quality

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent transforms qualitative visual inspection into quantitative measurement by detecting specific optical parameters (reflectivity ratios, absorption coefficients, colorimetric values). The system measures numerical parameters that directly correlate to surface treatment quality and coating adhesion potential, replacing subjective visual assessment with objective quantifiable data.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces optical properties (light reflection, absorption, scattering) as intermediary measurements that indirectly assess surface treatment quality and coating adhesion. Rather than directly measuring adhesion strength or surface roughness, the system uses optical characteristics as intermediate indicators that correlate to these critical quality attributes.

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

Enables accurate, quantitative assessment of laser treatment levels on composite material surfaces, improving the reproducibility and safety of manufacturing processes while ensuring adequate surface preparation for subsequent processing steps.

Implementation Method 1

activating the laser to produce a laser beam, and directing the laser beam from the laser to the carbon fiber epoxy-based composite material surface. The method further includes ablating an amount of material from the carbon fiber epoxy-based composite material surface

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

quantifying the level of ablative surface treatment of the carbon fiber epoxy-based composite material surface by conducting at least one surface analysis on a carbon fiber epoxy-based composite material surface, with the surface analysis selected from: gross analysis, Fourier transform infrared spectroscopy, color analysis, contact angle analysis, surface resistivity, optical interferometry, and optically stimulated electron emission

Methodology Applied

Scientific EffectFourier transform infrared spectroscopy:

Implementation Method 3

Methodology Applied

Scientific EffectOptical interferometry: Interference

Data Source

PatentUS11885725B2Surface analysis tools for process control of laser treatment of composites

Publication Date: 2024.01.30 THE BOEING CO

AI summary

Aspects of the present disclosure are directed methods and systems pertaining to the use of at least one methodology or technique for the purpose of at least one of either: 1) determining that a desired and predetermined level or “degree” of surface treatment of a composite substrate surface has or has not been conducted (e.g., laser treatment of a composite substrate surface); and 2) that a composite substrate surface has been laser treated.