Laser Transmission Scanning for EPS Density Mapping
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Solution Overview
Problem
Current methods for testing the density and homogeneity of components, particularly in expandable plastics, are labor-intensive and only allow for overall density determination, requiring destructive sampling and significant effort.
Innovation Solution
A non-destructive testing method using two-dimensional scanning with a laser beam to record spatially resolved transmission images of components translucent to infrared, visible, or ultraviolet light, allowing for spatially resolved density and homogeneity analysis, which can be integrated into manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If destructive sampling with buoyancy method is used for local density determination, then density measurement is possible, but testing effort and time increase significantly
Solution Approach 1:
The patent replaces the mechanical destructive sampling method (cutting components into segments and using buoyancy method) with an optical measurement system. A laser beam scans through the component, and a detector measures light transmission intensity. The system uses optical fields instead of mechanical cutting and water displacement to achieve density measurement, enabling non-destructive, rapid, and spatially resolved density determination throughout the component.
2Ease of manufacture
If overall density determination by volume and mass measurement is used, then testing is simple, but spatially resolved density information is lost
Solution Approach 1:
The patent applies segmentation by dividing the component into numerous small measurement points along the laser scan path. The laser beam scans through different locations (x, y coordinates) of the component, and the detector records transmission intensity at each point. This creates a spatially resolved density map that shows density variations throughout the component, maintaining measurement simplicity while gaining detailed spatial information.
3Measurement precision
If laser beam scanning is used for spatially resolved density measurement, then non-destructive testing with spatial resolution is achieved, but scattered light reduces measurement accuracy
Solution Approach 1:
The patent introduces a spatial filter as an intermediary element between the component and the detector. This spatial filter selectively transmits only the laser beam that has passed through the component while blocking scattered light. The filter acts as a mediator that separates the useful transmitted light from harmful scattered light, thereby improving measurement accuracy in spatially resolved density measurements.
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 rapid, cost-effective, and non-destructive testing of components with low densities, providing direct process control and quality assurance, reducing testing effort and time, and allowing for analysis of complex geometries and density fluctuations.
Implementation Method 1
a spatially resolved transmission image of the component, the area or the volume is recorded by two-dimensional scanning of the component, the area or the volume with a laser beam for which the component, the area or the volume is translucent... by measuring the intensity of the laser beam that has passed through the component or volume and is thus weakened
Data Source
Figure 1~2
AI summary
The method involves capturing a space-resolved transmission image of an expandable polystyrene component (3), an area of the component, or volume that is completely translucent or translucent in a region of electromagnetic radiation, by two-dimensional radiation of the component, the area or the volume using laser beam (2). An influence of scattered radiation (9) on the image is reduced by spatial filtering. The image is corrected using geometric data of the component, the area, or the volume, in order to obtain a thickness profile of the component, the area, or the volume based on the image. An independent claim is also included for a method for determining moisture content of a component.