Laser Surface Structuring of Metallic Press Plates
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Solution Overview
Problem
Current methods for producing surface structures on press plates, endless belts, and embossing rollers are complex, environmentally detrimental, and lack precision due to the reliance on etching processes and mask reproducibility issues, especially when creating high imaging precision and complex 3D structures.
Innovation Solution
A method using a laser to create surface structures on metallic press plates, endless belts, or cylindrical embossing rollers by employing digitized 3D topography data for precise positioning and focusing, allowing for partial surface removal with high precision and resolution, potentially omitting the need for etching processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional etching processes with masks are used to create surface structures, then complex 3D structures can be produced, but the process becomes environmentally detrimental, time-consuming, and suffers from mask reproducibility issues
Solution Approach 1:
The patent replaces the mechanical and chemical etching process with a laser-based system. The laser beam directly removes material to create the desired surface structure, eliminating the need for masks, etching chemicals, and multiple process steps. This substitution of the mechanical/chemical system with an optical system resolves the contradiction by maintaining precision while reducing process complexity and environmental impact.
Solution Approach 2:
The patent extracts and removes the problematic elements from the traditional process - specifically the masks and chemical etching agents. By using laser ablation, the method directly creates surface structures without requiring masks that suffer from reproducibility issues or environmental chemicals. This extraction of harmful and complex elements resolves the contradiction between precision and process complexity.
2Manufacturing precision
If multiple etching processes are performed in sequence to achieve high penetration depth and complex structuring, then surface quality improves, but processing time increases and environmental harm worsens
Solution Approach 1:
The laser process operates continuously to create the entire surface structure in a single pass. Unlike sequential etching processes that require multiple steps, mask applications, and chemical treatments, the laser system continuously ablates material along the programmed path, maintaining high surface quality while dramatically reducing processing time and eliminating environmental harm from repeated chemical processes.
Solution Approach 2:
The patent uses digitized 3D topography data of the desired surface structure to pre-program the laser path and parameters before processing begins. This preliminary preparation of digital models allows the laser to directly create the final surface structure in one continuous operation, eliminating the need for multiple sequential etching steps and mask applications, thus reducing time while maintaining precision.
3Measurement precision
If masks are applied through silk screening or photographic methods to achieve precise surface structuring, then imaging precision can be achieved, but mask alignment and reproducibility become problematic
Solution Approach 1:
The patent replaces the mask application system (silk screening or photographic methods) with a digital control system. The laser is positioned and focused using digitized 3D topography data that directly defines the surface structure to be created. This substitution eliminates masks entirely, resolving the reliability issues of mask reproducibility and alignment while maintaining high imaging precision through digital precision.
Solution Approach 2:
Instead of using physical masks that must be aligned and reproduced, the patent uses digital 3D topography data as a virtual template. This digital copy of the desired surface structure is stored computationally and used to control the laser path and focus, ensuring perfect reproducibility without the alignment and reproduction problems inherent in physical mask systems.
4Ease of manufacture
If conventional laser processing is used without digitized 3D topography control, then simpler equipment is needed, but positioning precision and focusing accuracy deteriorate
Solution Approach 1:
The patent implements a feedback system where digitized 3D topography data of the desired surface structure is used to continuously control laser positioning and focusing. The system reads the digital model and adjusts laser parameters in real-time based on the required surface features, maintaining high precision without requiring overly complex equipment. The feedback from the digital model guides the entire process, achieving precision through intelligent control rather than mechanical complexity.
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 method enables precise and repeatable surface structuring with reduced environmental impact, faster processing times, and improved reproducibility, as it directly generates the surface structure using laser technology, minimizing the need for multiple etching processes and complex mask alignment.
Implementation Method 1
partial removal of the surface through the at least one laser beam for reproducing a predeterminable surface structure
Data Source
AI summary
A method for producing a surface structure for a metallic press plate, endless belt or a cylindrical embossing roller through at least one laser and a device for using the method. In order to provide a cost effective production for the surface structure while using environmentally friendly techniques, it is proposed to use a laser which produces the entire surface structure through partial removal of a surface of a metallic press plate, endless belt or embossing roller to be processed. Thus, the laser is controlled by a provided 3D topography, wherein control of the laser is performed through obtained x, y and z coordinates in order to produce a depth structure, so that high portions and low portions are formed.