FIELD

The present disclosure generally relates to the field of processing substrates and, more particularly, to creating perforations in a substrate.

BACKGROUND

Prior technology with laser/scanner perforation on aerostructures materials utilizes a combination of n lasers in conjunction with a galvo-based x-y scanner. Although control of beam direction can be realized with the x-y scanners, it comes at speeds that are much slower than are desired for use in connection with aerostructure production. In a standard two galvanometer mirror system, the mirrors are commanded to some position and the laser is made to emit light. Although flexible in terms of pointing control in two planes, and adequate for many applications, this configuration yields a relatively slow process for creating perforations for aerostructures.

SUMMARY

A first aspect is embodied by creating one or more perforations on a substrate. A laser beam is output from a laser (e.g., one or more lasers may be utilized). A first polygon mirror includes a plurality of faces that are disposed on a perimeter of the first polygon mirror. The laser beam is reflected from a face of the rotating first polygon mirror. After being reflected by the first polygon mirror, the laser beam ultimately impacts a substrate to remove material from the substrate. The laser beam may be reflected from one or more faces of the first polygon mirror multiple times to ultimately define a first perforation on the substrate.

A number of feature refinements and additional features are applicable to the first aspect. These feature refinements and additional features may be used individually or in any combination. The following discussion is applicable to at least the first aspect. One or more perforations may be formed on the substrate for any appropriate purpose, such as for acoustics (dampening), aerodynamic drag (e.g., to improve laminar flow), surface conditioning (e.g., to enhance bonding; to enhance hydrophobic properties), cutting, trimming, welding, and the like. The substrate may be utilized as or by an aerostructure in one or more embodiments (e.g., a component of an airframe for aircraft, such as a fuselage, a wing, a flight control surface, inlet, engine duct, interiors, or the like).

The substrate may formed from any appropriate material or combination of materials, such as a composite, CFRP (carbon fiber reinforced polymer), CMC (ceramic matrix composite), GFRP (glass fiber reinforced polymer), metal, alloys, ceramics, or the like. The substrate may be of any appropriate configuration at the time when one or more perforations are formed on surface of the substrate, such as a plate or plate-like structure, a curved structure, a honeycomb structure, a film, or the like. The substrate may be of any appropriate thickness.

The first perforation may extend completely through a thickness of the substrate, or the first perforation may extend only partially through a thickness of the substrate to define a concave depression (e.g., the first perforation may be in the form of a blind hole in this instance). Multiple executions of the laser beam being reflected by one or more faces of the rotating first polygon mirror, and the subsequent impacting of the laser beam on the substrate, may be needed to one or more of: 1) define a desired depth of the first perforation in the substrate; 2) define a desired perimeter configuration for the first perforation; and 3) define a desired size for the first perforation. A first perforation of any desired perimeter configuration may be formed on the substrate, including without limitation circular, oval, square, rectangular, hexagonal, a line or slot, star-shaped, and the like. In various embodiments, each perforation that is formed on the substrate may be of any appropriate size. Incorporating multiple perforations on a substrate may define an open area of any appropriate magnitude. This open area is a ratio of an area of the surface of the substrate that is occupied by the various perforations, divided by an area of this surface of the substrate that is within an outer boundary of this surface that includes these perforations.

The laser may be of any appropriate type and/or configuration. An optical path may be characterized as extending from the laser to the substrate. One or more optical components may be disposed between the first polygon mirror and the substrate along this optical path. The first polygon mirror may be rotated by any appropriate drive source. In one or more embodiments, the first polygon mirror rotates at a constant rotational velocity throughout the definition of one or more perforations on the substrate by reflecting the laser beam to predetermined locations on the substrate. The laser beam may be pulsed from the laser, and furthermore timed to a rotational speed of the first polygon mirror, to define one or more perforations on the substrate that each have a predetermined perimeter configuration and that are each disposed on the substrate at a predetermined location. Each perforation that is formed in the substrate may be of a common configuration and size, although such may not be the case for one or more applications. A common perforation spacing may be used throughout the portion of the substrate in which perforations are formed, although such may not be the case for one or more applications.

A first plurality of perforations may be defined on the substrate by reflecting the laser beam from one or more faces of the rotating first polygon mirror, and may include the first perforation. Each perforation of the first plurality of perforations may be spaced from a remainder of the first plurality of perforations on the substrate. Any appropriate spacing may be utilized between the various perforations of the first plurality of perforations, including having a common spacing between each adjacent pair of perforations of the first plurality of perforations. Different sets of perforations of the first plurality of perforations may be disposed in different row sets on the substrate that each correspond with an x dimension of the substrate, where adjacent row sets on the substrate may be spaced from one another in a y dimension of the substrate. Herein, the x dimension and the y dimension of the substrate may be orthogonal to one another.

An optical system may be characterized as including the first polygon mirror and the laser. This optical system may be disposed in a first position where the above-noted first plurality of perforations are defined on the substrate. The optical system may be moved from this first position to a second position. A second plurality of perforations may be defined on the substrate by reflecting the laser beam from one or more faces of the rotating first polygon mirror and with the optical system remaining in the second position. The first plurality of perforations and the second plurality of perforations may be defined and/or formed on non-overlapping portions of the substrate. Each perforation of the second plurality of perforations may be spaced from a remainder of the second plurality of perforations on the substrate. Any appropriate spacing may be utilized between the various perforations of the second plurality of perforations, including having a common spacing between each adjacent pair of perforations of the second plurality of perforations. Different sets of perforations of the second plurality of perforations may be disposed in different rows sets on the substrate that each correspond with an x dimension of the substrate, where adjacent row sets on the substrate may be spaced from one another in a y dimension of the substrate.

In at least one embodiment, each face of the plurality of faces used by the first polygon mirror may be flat or planar, and furthermore may be disposed parallel to a rotational axis of the first polygon mirror. A first mirror may be disposed at any appropriate position along the noted optical path (e.g., disposed between the first polygon mirror and the substrate along the noted optical path), and this first mirror may be incrementally moved between a first plurality of fixed positions. In each fixed position of the first plurality of fixed positions for the first mirror, the first polygon mirror may be used to reflect the laser beam to impact the substrate at a plurality of positions on the substrate that are along a row that corresponds with an x dimension for the substrate. Disposing the first mirror in each of a plurality of fixed positions may be used to define one or more perforations on the substrate, including where multiple perforations are disposed along a row set defined by a plurality of the above-noted rows (e.g., each such row may correspond with a different, dedicated fixed position of the first mirror).

In at least one embodiment, each face of the plurality of faces used by the first polygon mirror may be flat or planar, and furthermore each such face may be disposed in a different orientation relative to a rotational axis of the first polygon mirror. Each face may correspond with a different row on the substrate that corresponds with the x dimension of the substrate. A first mirror may be disposed at any appropriate position along the noted optical oath (e.g., disposed between the first polygon mirror and the substrate along the noted optical path). This first mirror may be maintained in a first fixed position as reflections of the laser beam from the various faces of the first polygon mirror define the entirety of the first perforation in the substrate. Multiple first perforations may be formed on the substrate in a first row set, in spaced relation to one another, with this first mirror remaining in the noted first fixed position. The first mirror may be moved to a second fixed position to define one or more first perforations on the substrate in a second row set that is spaced from and parallel to the noted first row set, and while the first mirror is retained in this second fixed position.

A second polygon mirror may be used to define one or more perforations on the substrate. This second polygon mirror may include a plurality of faces that are disposed on a perimeter of the second polygon mirror. A first rotational axis of the first polygon mirror and a second rotational axis of the second polygon mirror may be disposed in different orientations relative to one another. The first polygon mirror may be used to define an extent of the one or more perforations in an x dimension of the substrate, while the second polygon mirror may be used to define an extent of one or more perforations in a y dimension of the substrate.

Various embodiments include using the above-noted first polygon mirror, the above-noted second polygon mirror, a movable first positioning mirror, and a moveable second positioning mirror. Each of the first polygon mirror, the second polygon mirror, the first positioning mirror, and the second positioning mirror may be disposed at any appropriate position along the optical path proceeding from the laser to the substrate. The first polygon mirror may be characterized as controlling formation of one or more perforations in at least a first dimension on the substrate (e.g., an x dimension). The second polygon mirror may be characterized as controlling formation of one or perforations in a second dimension (e.g., a y dimension) that is orthogonal to the first dimension. The movable second positioning mirror may be used to control formation of perforations in different quadrants relative to the first dimension (e.g., in a first quadrant and in a second quadrant that occupy different positions in the first dimension; in a third quadrant and in a fourth quadrant that occupy different positions in the first dimension). The movable first positioning mirror may be used to control formation of perforations in different quadrants relative to the second dimension (e.g., in a first quadrant and in a third quadrant that occupy different positions in the second dimension; in a second quadrant and in a fourth quadrant that occupy different positions in the second dimension). The first positioning mirror could also be used to control the formation of perforations in a given quadrant, but still in the noted second dimension.

The first polygon mirror may be characterized as controlling formation of one or more perforations in at least a first dimension on the substrate (e.g., an x dimension). Another mirror may be utilized to control formation of one or more perforations in a second dimension (e.g., a y dimension) that is orthogonal to the first dimension on the substrate. Such an additional mirror could be the above-noted first mirror, the second polygon mirror, or both. As discussed above, the first polygon mirror may be configured to control formation of one or more perforations in a common row in both the x and y dimensions (although the noted first mirror and/or second polygon mirror may be used to allow the first polygon mirror to form one or more perforations in a different row in such a case).

A second aspect is embodied by a perforation system that includes a movable base, a laser, a first polygon mirror, and a controller. The laser is mounted in a fixed position on the movable base, while the first polygon mirror is rotatably mounted on the movable base. The controller is configured to dispose the movable base in each of a plurality of fixed positions, and furthermore to operate the laser and rotate the first polygon mirror to define a plurality of perforations throughout a predetermined area of a substrate for each of the plurality of fixed positions for the movable base.

A number of feature refinements and additional features are applicable to the second aspect. These feature refinements and additional features may be used individually or in any combination. The following discussion is applicable to at least this second aspect. The second aspect may be utilized to execute the method associated with the first aspect, and as such the perforation system may include a second polygon mirror as discussed above in relation to the first aspect.

A third aspect is embodied by a method of processing a surface of an aerostructure. A laser beam is output from a laser. A first polygon mirror includes a plurality of faces that are disposed on a perimeter of the first polygon mirror. The laser beam is reflected from a face of the rotating first polygon mirror. The laser beam that is reflected by the first polygon mirror is used to define a plurality of perforations on a surface of the aerostructure.

A number of feature refinements and additional features are applicable to the third aspect. These feature refinements and additional features may be used individually or in any combination. The following discussion is applicable to at least this third aspect. Initially, the various features discussed above in relation to the first aspect may also be utilized by this third aspect. Representative materials for the aerostructure include without limitation the substrate materials noted above in relation to the first aspect. An open area of any appropriate magnitude may be defined by the perforations formed on the aerostructure.

Any feature of any other various aspects that is intended to be limited to a “singular” context or the like will be clearly set forth herein by terms such as “only,” “single,” “limited to,” or the like. Merely introducing a feature in accordance with commonly accepted antecedent basis practice does not limit the corresponding feature to the singular (e.g., indicating that a substrate includes “a perforation” alone does not mean that the substrate includes only a single perforation). Moreover, any failure to use phrases such as “at least one” also does not limit the corresponding feature to the singular (e.g., indicating that a substrate includes “a perforation” alone does not mean that the substrate includes only a single perforation). Use of the phrase “at least generally” or the like in relation to a particular feature encompasses the corresponding characteristic and insubstantial variations thereof (e.g., indicating that a perforation is at least generally circular encompasses the perforation being circular). Finally, a reference of a feature in conjunction with the phrase “in one embodiment” does not limit the use of the feature to a single embodiment.

Various aspects are also addressed by the following paragraphs and in the noted combinations:

In one embodiment, a method for creating a perforation in a substrate, comprising:

directing a laser beam from a laser;

rotating a first polygon mirror comprising a plurality of faces that are disposed on a perimeter of said first polygon mirror;

reflecting said laser beam from a face of said plurality of faces;

removing material from a substrate, after said reflecting step, by impacting said laser beam on said substrate; and

repeating said reflecting and removing steps a plurality of times to define a first perforation in said substrate.

In another embodiment, said first perforation extends completely through a thickness of said substrate.

In another embodiment, said first perforation extends only partially through a thickness of said substrate to define a concave depression on said substrate.

In another embodiment, multiple executions of said reflecting and removing steps are required to define a desired depth of said first perforation.

In another embodiment, multiple executions of said reflecting and removing steps are required to define a desired perimeter configuration of said first perforation.

In another embodiment, multiple executions of said reflecting and removing steps are required to define both a desired depth of said first perforation and a desired perimeter configuration of said first perforation.

In another embodiment, said rotating step comprises continually rotating said polygon mirror at a constant rotational velocity throughout said repeating step.

In another embodiment, further comprising:

defining a first plurality of perforations on said substrate using said repeating step, wherein each perforation of said first plurality of perforations is spaced from a remainder of said first plurality of perforations, and wherein said first plurality of perforations comprises said first perforation.

In another embodiment, different portions of said first plurality of perforations are disposed in different row sets on said substrate that correspond with an x dimension of said substrate, and wherein adjacent row sets on said substrate are spaced from one another in a y dimension.

In another embodiment, further comprising:

moving an optical system from a first position to a second position, wherein said optical system comprises said first polygon mirror and said laser, and wherein said optical system is in said first position for said defining a first plurality of perforations step; and

defining a second plurality of perforations on said substrate using said repeating step, wherein each perforation of said second plurality of perforations is spaced from a remainder of said second plurality of perforations, wherein said first plurality of perforations and said second plurality of perforations are defined in non-overlapping portions of said substrate, and wherein said optical system is in said second position for said defining a second plurality of perforations step.

In another embodiment, a movable mirror and said first polygon mirror are in an optical path proceeding from said laser to said substrate, wherein said first polygon mirror defines said plurality of perforations in at least a first dimension and said movable mirror defines at least part of at least some of said plurality of perforations in a second dimension that is orthogonal to said first dimension.

In another embodiment, said substrate comprises an aerostructure.

In another embodiment, each said face of said plurality of faces is a planar surface and is parallel to a rotational axis of said first polygon mirror.

In another embodiment, further comprising:

executing a first repeating step comprising repeating said reflecting and removing steps a plurality of times at spaced locations in each of a first plurality of rows that each correspond with an x dimension of said substrate, wherein each row of said first plurality of rows are spaced from one another in a y dimension of said substrate, wherein said first plurality of rows define a first row set, and wherein a plurality of said first perforations are defined in said first row set and are spaced from one another along said first row set.

In another embodiment, further comprising incrementally moving a first mirror between a first plurality of fixed positions, wherein each fixed position of said first plurality of fixed positions corresponds with a different said row of said first row set.

In another embodiment, further comprising:

executing a second repeating step comprising repeating said reflecting and removing steps a plurality of times at spaced locations in each of a second plurality of rows that each correspond with said x dimension of said substrate, wherein each row of second said plurality of rows are spaced from one another in said y dimension of said substrate, wherein said second plurality of rows define a second row set that is spaced from said first row set in said y dimension, and wherein a plurality of said first perforations are defined in said second row set and are spaced from one another along said second row set.

In another embodiment, further comprising incrementally moving said first mirror between a second plurality of fixed positions that are each different from said first plurality of fixed positions, wherein each fixed position of said second plurality of fixed positions corresponds with a different said row of said second row set.

In another embodiment, said first mirror is disposed between said laser and said first polygon mirror along an optical path proceeding from said laser to said substrate.

In another embodiment, each said face of said plurality of faces is a planar surface and is disposed at a different angle relative to a rotational axis of said first polygon mirror.

In another embodiment, said reflecting step is executed in relation to each of said plurality of faces to define an entirety of said first perforation.

In another embodiment, further comprising:

executing a first repeating step comprising repeating said reflecting and removing steps a plurality of times at spaced locations along a row set that corresponds with an x dimension of said substrate, wherein a plurality of said first perforations are defined in said row set and are spaced from one another within said row set.

In another embodiment, further comprising maintaining a first mirror in a first fixed position until completion of said first perforation, wherein said first mirror is disposed in an optical path proceeding from said laser to said substrate.

In another embodiment, further comprising:

incrementing said first mirror to a second fixed position; and

repeating said reflecting and removing steps a plurality of times to define a second perforation in said substrate and with said first mirror remaining in said second fixed position, wherein said first and second perforations are spaced from one another in a y dimension of said substrate.

In another embodiment, further comprising the steps of:

rotating a second polygon mirror comprising a plurality of faces that are disposed on a perimeter of said second polygon mirror;

wherein said first polygon mirror comprises a first rotational axis, wherein said second polygon mirror comprises a second rotational axis, and wherein said first rotational axis is disposed in a different orientation than said second rotational axis.

In another embodiment, said second polygon mirror is disposed in an optical path proceeding from said laser to said substrate.

In another embodiment, said first polygon mirror is used to define an extent of said first perforation in an x dimension of said substrate, and wherein said second polygon mirror is used to define an extent of said first perforation in a y dimension of said substrate.

In another embodiment, said first polygon mirror rotates at a higher rotational speed than said second polygon mirror.

In another embodiment, a number of said faces of said first polygon mirror is the same as a number of said faces of said second polygon mirror.

In another embodiment, a number of said faces of said first polygon mirror is different from a number of said faces of said second polygon mirror.

In another embodiment, said first polygon mirror and said second polygon mirror rotate at a common rotational speed.

In another embodiment, said repeating step comprises impacting said laser beam on each of a plurality of different locations along a row set that extends in an x dimension of said substrate and that defines a plurality of said first perforations within said row set that are spaced from one another in said x dimension.

In another embodiment, said repeating step comprises impacting said laser beam on each of a plurality of different locations within each row of each row set of a plurality of row sets, said method further comprising:

defining a plurality of said first perforations in each said row set using said repeating step.

In another embodiment, all of said plurality of first perforations in a given said row set are defined prior to initiating execution of said defining step in a different said row set.

In another embodiment, further comprising:

incrementally moving a first mirror between a plurality of fixed positions, wherein each fixed position of said plurality of fixed positions corresponds with a different said row set of said plurality of row sets.

In another embodiment, said first mirror is located between said second polygon mirror and said substrate along an optical path proceeding from said laser to said substrate, and wherein said second polygon mirror is located between said first mirror and said first polygon mirror along said optical path.

In another embodiment, said defining a plurality of said first perforations comprises:

a first sequencing step comprising sequencing said laser beam a single time through each said row set of said plurality of row sets to impact a first plurality of different locations within each said row set; and

executing a second sequencing step after said first sequencing step, and comprising sequencing said laser beam a single time through each said row set of said plurality of row sets to impact a second plurality of different locations within each said row set.

In another embodiment, further comprising:

incrementally moving a first mirror between first and second fixed positions, wherein said first mirror is in said first fixed position for said first sequencing step, and wherein said first mirror is in said second fixed position for said second sequencing step.

In another embodiment, said first mirror is located between said second polygon mirror and said substrate along an optical path proceeding from said laser to said substrate, and wherein said second polygon mirror is located between said first mirror and said first polygon mirror along said optical path.

In another embodiment, said second polygon mirror controls an impact location of said laser beam on said substrate in a y dimension, and wherein said first polygon mirror controls said impact location of said laser beam on said substrate in an x dimension.

In another embodiment, further comprising using said substrate as an aerostructure.

In another embodiment, further comprising using said method to acoustically treat said substrate.

In another embodiment, further comprising using said method to address aerodynamic drag on said substrate.

In another embodiment, said x dimension is orthogonal to said y dimension.

In one embodiment, a perforation system, comprising:

a movable base;

a laser mounted in a fixed position on said movable base;

a first polygon mirror rotatably mounted on said movable base; and

a controller configured:to dispose said movable base in a plurality of fixed positions; andto operate said laser and to rotate said first polygon mirror at a fixed rotational speed to define a plurality of perforations throughout a predetermined area of a substrate for each of said plurality of fixed positions of said movable base.

In another embodiment, said perforation system is configured to execute the above-described method

In another embodiment, further comprising a first mirror mounted on said movable base.

In another embodiment, further comprising a second polygon mirror rotatably mounted on said movable base and a first mirror mounted on said movable base.

In another embodiment, said first polygon mirror is disposed between said laser and second polygon mirror along an optical path.

