Laser Machining Apparatus for Hollow Object Interior Etching
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Solution Overview
Problem
Current etching technologies are unable to effectively pattern the interior surfaces of hollow, three-dimensional objects made of ferrous alloys or other substrates due to the lack of suitable tools and processes for accessing and processing internal surfaces.
Innovation Solution
A laser machining apparatus and method that includes a collimated laser beam, focusing lens, reflector, and adjustment mechanism, allowing for precise focusing and movement within the hollow object to create patterns on internal surfaces using laser ablation, chemical etching, or electrochemical etching, with a system for coating application, pattern generation, and etching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional etching tools and processes are used, then exterior surfaces of objects can be etched, but interior surfaces of hollow objects cannot be accessed or etched
Solution Approach 1:
The patent replaces traditional mechanical etching tools with a laser-based system that can be inserted through small openings. The laser beam is focused onto the interior surface using a focusing lens, enabling non-contact material removal without requiring mechanical contact or large access openings.
Solution Approach 2:
The invention transitions from mechanical tool-based etching (requiring physical access to the surface) to optical field-based etching (laser beam that can be directed through small openings). This dimensional shift allows the etching process to access interior surfaces of hollow objects that were previously inaccessible to mechanical tools.
2Adaptability or versatility
If a fixed focal length laser system is used, then the system is simple, but it cannot accommodate varying distances to non-uniform interior surfaces
Solution Approach 1:
The patent implements a dynamic adjustment mechanism that allows the focal length of the laser system to be varied. This enables the system to maintain proper focus on non-uniform interior surfaces at varying distances, accommodating different geometries and access conditions without requiring a completely different system for each case.
Solution Approach 2:
The laser machining apparatus is designed as a universal system that can handle various interior surface geometries and access conditions. By incorporating adjustable focal length capability, a single system can serve multiple functions across different object types and configurations, rather than requiring specialized systems for each scenario.
3Area of stationary object
If the distance between the laser system and interior surface varies, then different surface areas can be reached, but focus precision is lost
Solution Approach 1:
The system dynamically adjusts the focal length based on the distance to the target surface. This allows the laser to maintain precise focus whether working on surfaces close to the opening or deeper within the hollow object, preserving manufacturing precision across the entire accessible surface area.
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 the creation of complex patterns on internal surfaces of hollow objects with varying shapes and sizes, overcoming the limitations of traditional etching methods by providing precise control and adaptability for both small openings and non-uniform interior geometries.
Implementation Method 1
Machining may include removal or deposition of materials such as laser ablation
Implementation Method 2
a focusing lens for focusing the laser beam to provide a focal length (f)
Implementation Method 3
a reflector for changing a direction of the laser beam
Implementation Method 4
Metal ions from the exposed portions of the substrate are dissolved or dislocated into the electrolyte at a rate proportional to the current applied
Data Source
AI summary
Systems and methods for etching complex patterns on an interior surface of a hollow object are disclosed. A method generally includes positioning a laser system within the hollow object with a focal point of the laser focused on the interior surface, and operating the laser system to form the complex pattern on the interior surface. Motion of the laser system and the hollow object is controlled by a motion control system configured to provide rotation and/or translation about a longitudinal axis of one or both of the hollow object and the laser system based on the complex pattern, and change a positional relationship between a reflector and a focusing lens of the laser system to accommodate a change in distance between the reflector and the interior surface of the hollow object.