Laser Engraving Roller Blank with Optical Focus Control

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Solution Overview

Problem

Existing methods for manufacturing rollers, such as etching processes, lack the precision and stability needed for achieving high-resolution embossed profiles, particularly for rollers made of harder materials like steel, which are prone to mechanical wear and require advanced profile stability.

Innovation Solution

The method involves using laser light to remove material from a roller blank, with the focus distance adjusted based on optical measurements to ensure precise engraving, allowing for deeper profiles and increased mechanical stability, and utilizing multiple engraving steps and brushes to achieve engraving depths of over 3 mm.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If etching processes are used to produce roller profiles, then manufacturing is simpler, but resolution and precision of the embossed profile are insufficient

Engineering Contradiction:

Improveresolution of embossed profileVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces traditional mechanical etching processes with laser technology for material removal. The laser beam precisely ablates material from the roller blank to create the embossed profile, achieving superior resolution and precision while maintaining manufacturing feasibility through computer-controlled laser positioning and focusing systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If rollers are made of harder materials like steel to increase wear resistance, then stability against mechanical wear improves, but the complexity of achieving precise profiles increases

Engineering Contradiction:

Improvestability against mechanical wearVSAvoidcomplexity of profile application

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies laser technology to engrave profiles directly into hard materials like steel rollers. The laser's ability to precisely remove material from hard surfaces without mechanical contact enables the creation of complex, high-resolution embossed profiles on wear-resistant materials that would be difficult or impossible to achieve with traditional mechanical machining methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If the focus position of laser light is not precisely adjusted, then the engraving process is simpler, but the resolution and quality of the embossed profile deteriorates

Engineering Contradiction:

Improvequality of embossed profileVSAvoidfocus adjustment mechanism

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent incorporates optical distance measurement systems that provide feedback on the actual distance between the laser focus and the roller blank surface. This feedback enables real-time adjustment of the focus position to maintain optimal engraving conditions, ensuring high profile resolution and quality while compensating for variations in roller diameter or positioning.

Inventive Principle:

Principle #23Feedback

4Reliability

If engraving depth is increased to improve profile stability, then mechanical wear resistance improves, but the complexity of the engraving process increases

Engineering Contradiction:

Improveprofile stabilityVSAvoidengraving process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent employs multi-pass laser engraving where the laser repeatedly traverses the same area in multiple passes to achieve the desired engraving depth. This periodic action allows progressive material removal while maintaining precise control over the final profile geometry, enabling deep engravings with high precision without requiring complex single-pass machining operations.

Inventive Principle:

Principle #19Periodic action

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 enables the creation of rollers with higher resolution and stability against mechanical wear, allowing for more precise and efficient embossing processes, including the reprocessing of worn rollers to maintain high embossing quality.

Implementation Method 1

material is removed from the roller blank (1) using laser light (2)

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

a distance (4) of the focus (5) of the laser light from the longitudinal axis L of the roller blank (1) being set as a function of an optical distance measurement

Methodology Applied

Scientific EffectOptical distance measurement: LIDAR

Data Source

PatentEP4286160A1Embossing roll

Publication Date: 2023.12.06 GRAVION GMBH & CO KG

Figure 1~3
Figure 4~5

AI summary

A method for engraving a roller blank (1) is thus proposed, wherein material is removed from the roller blank (1) using laser light, and the distance (4) of the focus (5) of the laser light from the longitudinal axis (L) of the roller blank (1) is set as a function of an optical distance measurement. Furthermore, a method for reconditioning a roller (18) is proposed, wherein, after removing an outer layer (23) of the roller (18), a method according to the invention for engraving a roller blank (1) is carried out. It is also proposed to use a roller (18) produced by a method according to the invention for embossing a material (see Fig. 1).