Continuous Laser Cutting of Split Sleeves Without Feed Stops

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Solution Overview

Problem

Conventional cutting methods for self-wrapping, woven or braided split sleeves, such as hot knife cutting, require stopping the feed for each cut, which is inefficient and can lead to fraying, whereas laser cutting with a continuous feed and angled sweep path allows for uninterrupted cutting and reduced fraying.

Innovation Solution

A laser cutting apparatus and method that continuously feeds self-wrapping, woven or braided split sleeve material, using a mandrel to maintain the material's shape and prevent fusion of the longitudinal split, with a laser beam cutting from one side to the other in a path angled to match the feed rate, enabling straight cuts without stopping the feed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If hot knife cutting is used to cut split sleeves, then the material is cut relatively easily with melting that helps prevent fraying, but the feed must be stopped for every cut which reduces processing speed

Engineering Contradiction:

Improveease of cuttingVSAvoidprocessing speed

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent replaces the mechanical hot knife cutting system with a laser-based cutting system. The laser beam cuts the split sleeve material without requiring physical contact or mechanical pressure, eliminating the need to stop the feed mechanism while maintaining effective cutting through thermal energy concentration.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The laser cutting system enables continuous operation by maintaining an uninterrupted feed of the split sleeve material through the laser beam. The laser follows the material continuously, performing the cutting action without interruption, thereby eliminating the stop-start cycle inherent in hot knife cutting and significantly improving productivity.

Inventive Principle:

Principle #20Continuity of useful action

2Reliability

If hot knife cutting is used to cut split sleeves, then cutting can be performed with melting to prevent fraying, but the continuous feed must be stopped and started for each cut which increases cycle time

Engineering Contradiction:

Improvefray preventionVSAvoidfeed stopping and starting time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The mechanical hot knife system is replaced with a laser cutting system that uses concentrated optical energy to melt and sever the material. This substitution allows the feed to continue moving uninterrupted while the laser performs the cutting action, eliminating the time loss associated with stopping and starting the feed for each cut.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The cutting method transitions from mechanical contact-based heating (hot knife) to optical-based heating (laser). This parameter change in the energy delivery mechanism enables continuous material feed while maintaining the thermal melting effect that prevents fraying, thereby reducing cycle time without sacrificing cut quality.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If a laser beam is swept straight across the material perpendicular to the longitudinal axis, then a clean cut is achieved, but the feed must be stopped for each cut which reduces efficiency

Engineering Contradiction:

Improvecut straightnessVSAvoidprocessing efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The laser beam delivery system transitions from a static perpendicular sweep to a dynamic angled sweep that follows the material feed motion. The laser beam moves at an angle relative to the material longitudinal axis, synchronizing the cutting action with the continuous material flow, thereby maintaining cut precision while enabling uninterrupted feeding and improving overall processing efficiency.

Inventive Principle:

Principle #15Dynamics

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 significantly improves processing speed by eliminating the need for stopping and starting the feed, while the laser-induced melting helps prevent fraying, resulting in efficient and clean cuts.

Implementation Method 1

Each cut is made by sweeping a laser beam across the continuously fed material

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

Some melting of the material occurs at the cut and helps prevent fraying

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS20230398631A1Laser cutting self-wrapping, split sleeves from continuous feed

Publication Date: 2023.12.14 ROFIN SINAR TECH LLC

AI summary

An apparatus, and associated method, laser cuts self-wrapping, woven or braided split sleeves from a continuous feed of sleeve material by sweeping a laser beam across the continuously fed material. Instead of sweeping the laser beam straight across the material in a direction perpendicular to the longitudinal axis of the material, the sweep path is angled to follow the feed rate of the material while the laser beam cuts through the material from one side to the other. Thus, a straight cut may be completed without stopping the feed. The apparatus includes a mandrel tor expanding the material before intersection with the laser beam to open a gap at the longitudinal split. The mandrel has a wedge-shaped tip with an end-surface profile that is at an oblique angle to the direction of motion of the material. The oblique angle at least approximately matches the sweep angle of the laser beam.