Sensor Film Micro-Milling for Crack Detection
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Solution Overview
Problem
Existing methods for producing sensor films for comparative vacuum measurement, such as laser lithography, are complex, costly, and difficult to control, leading to inefficiencies in producing precise air and vacuum channels for crack detection in aircraft structures.
Innovation Solution
A micro-milling method is used to create predetermined gallery patterns on the sensor film, allowing for rapid and cost-effective production with smoother edges and precise control over depth and width, reducing the need for multiple passes and minimizing operational costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser lithography is used to produce galleries in the sensor film, then the galleries can be created with precise depth control, but the production time increases and multiple passes are frequently necessary
Solution Approach 1:
The patent replaces the mechanical milling apparatus with a laser-based lithography system. The laser beam vaporizes the plastic material to create galleries, eliminating the need for mechanical contact and multiple passes. The laser parameters (intensity, feed rate, number of passes) are precisely controlled to achieve the desired gallery depth, substituting mechanical removal with optical-thermal processing.
Solution Approach 2:
The laser lithography process utilizes phase transition of the plastic material from solid to vapor through localized heating. The laser beam heats the plastic material to its vaporization point, causing it to transition directly to vapor and be removed from the sensor film, creating the gallery structure in a single pass with precise depth control.
2Manufacturing precision
If laser lithography is used to produce galleries, then the desired gallery pattern can be achieved, but the operational costs and complexity increase
Solution Approach 1:
The patent replaces complex mechanical milling systems with a laser lithography system. The laser apparatus with controlled beam movement substitutes for mechanical milling equipment, achieving precise gallery patterns through optical rather than mechanical means. This reduces mechanical complexity while maintaining or improving pattern accuracy.
Solution Approach 2:
The patent controls the laser process by adjusting parameters such as laser intensity, feed rate, and number of passes. By varying these parameters, the desired gallery pattern is achieved with precise control over depth and geometry, replacing complex mechanical adjustments with controllable energy parameters.
3Ease of manufacture
If replica methods are used to produce air and vacuum channels, then the channels can be created in the sensor film, but the production process becomes complex and costly
Solution Approach 1:
The patent replaces the multi-step replica molding process with direct laser lithography. Instead of creating a negative mold, pouring monomeric/oligomeric mixture, and hardening, the laser directly vaporizes the plastic film to create the gallery channels in a single step, dramatically simplifying the manufacturing process.
Solution Approach 2:
The patent extracts the essential function of channel creation from the complex replica process. By using laser lithography, only the necessary step of removing material to form channels is performed, eliminating the intermediate steps of mold creation, material pouring, and hardening that characterize the replica method.
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
The micro-milling method enables more reliable crack detection by producing smoother gallery walls, reducing production time and costs, and allowing for the measurement of smaller cracks with increased precision and reliability.
Implementation Method 1
a milling apparatus or a micro-milling apparatus may generate a predetermined gallery course along the sensor film surface
Implementation Method 2
The plastic or the polymer is vaporized by the laser beam because of the local heat introduction
Data Source
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AI summary
The present invention relates to a production method for producing a sensor film (1) for measuring cracks of a material surface using the comparative vacuum measurement method. A gallery (2) having a predetermined gallery course is milled along a surface of the sensor film (1) using a milling apparatus (3). The sensor film (1) comprises a plastic material.