Patent Application
20210362270
The present disclosure pertains to the laser ablation systems and methods, and in some instances to laser ablation fume and contaminant capturing systems. Example systems can capture hazardous materials and fumes created by laser ablation and laser processing to protect the environment, people, and laser equipment from exposure to these materials and fumes
A detailed description is set forth regarding the accompanying drawings. The use of the same reference numerals may indicate similar or identical items. Various embodiments may utilize elements and/or components other than those illustrated in the drawings, and some elements and/or components may not be present in various embodiments. Elements and/or components in the figures are not necessarily drawn to scale. Throughout this disclosure, depending on the context, singular and plural terminology may be used interchangeably.
One example system includes a housing forming a partial enclosure that is configured to be placed against a target surface; a transparent window being integrated into a top surface of the housing, the transparent window is configured to allow for the transmission of laser output to the target surface; and an outlet port for establishing a negative pressure inside the housing, wherein air is drawn into the housing through a first inlet port, the air carries contaminants created during ablation of the target surface by the laser output, out of the outlet port.
Another example system includes a housing that is configured to be placed against a target surface; a port such as a tubular port being integrated into a surface of the housing, the tubular port being configured to allow for the transmission of laser output to the target surface; and an outlet port for drawing air inside the housing through the tubular port, the air carrying contaminants created during ablation of the target surface by the laser scan pattern out of the outlet port. The port can have other geometric shapes such as square, oval, or polygon.
Yet another example system includes an enclosure having a top surface and sides; a transparent window associated with the top surface, the transparent window allowing transmission of laser output through the transparent window to the target surface; and an outlet port for drawing air into an opening in the housing, the air mixing with and carrying away contaminants created during ablation of the target surface by the laser output.
Laser ablation/cleaning methods are used to process, alter, clean, or remove a range of unwanted layers of material from various substrates such as contaminants, corrosion, coatings, paint, biological substances, organic substances, toxic substances, and hazardous materials. These methods can also be used to create a texture on a surface or to decontaminate a surface.
The ablated and vaporized materials and contaminants created by the laser ablation process are typically captured by some form of fume extraction system where the fume extractor is positioned in close proximity to the laser process so that the fumes/contaminants are captured as they are removed from the surface by the laser. The fume extractor can be positioned above, next to, below, behind, at an angle to, perpendicular, or parallel to the laser cleaning process. This setup is functional but can have some inherent problems. The fume extractor needs to be positioned correctly to capture the fumes. The fumes are then collected through a series of filters such as HEPA and carbon filters. Problems such as an incorrect position of the fume extractor, strong wind or drafts, insufficient vacuum draw, or an obstruction to the draw or flow of the fumes could potentially allow some of the air-born contaminants to escape collection. Laser ablated particles can also eject off of a surface in all directions and can have more momentum when higher laser powers or higher fluence levels are used during cleaning. This is of particular concern when dealing with hazardous or toxic materials such as carcinogens, lead, radioactive materials, and biologically hazardous materials such as bacteria, mold, or viruses. Another concern is that the laser equipment itself is at risk of being contaminated by any of these air-born materials/contaminants that are not captured by the fume extraction and deposit on the laser equipment itself. The laser system, scanner, optics, robotics, and functional components may get contaminated by laser-ablated hazardous materials which may be time-consuming, expensive, difficult, or in some cases impossible to remove. For example, in the case of nuclear decontamination cleaning of radioactive materials or biohazard cleaning, getting these contaminants on the laser equipment could necessitate the need for disposal or replacement of expensive parts of the equipment or all of the equipment. This present invention remedies several problems such as: ensuring full capture of all laser-ablated/vaporized material, ensuring that expensive laser equipment and laser cleaning system components do not get contaminated by hazardous materials, ensuring personnel operating laser equipment are not exposed to hazardous materials, allowing for easy replacement in the field and continued workflow when dealing with hazardous environments and materials, and the fume capture chamber can be made in a geometric shape that is optimal for cleaning a particular surface or object shape.
The systems and methods disclosed herein provide cost-effective and efficient mechanisms for remediating laser cleaning hazardous materials. Rather than place a fume extraction system near a laser ablation process, the laser ablation process is contained with the system (also referred to as a fume extraction system). This ensures everything is captured and does not escape and contaminants the laser equipment, surroundings, or personnel.
The systems and methods disclosed herein provide cost-effective and efficient mechanisms for remediating laser cleaning materials that are flammable and for laser cleaning and processing materials and surfaces in environments with flammable or combustible materials present in the environment.
The fume extraction design is an enclosed system with a window or windows that the laser fires through to reach the unwanted layer or contaminant that is to be removed while it is in a vacuum negative pressure environment. The portion/face of the chamber that comes in contact with the surface being treated is open to allow the laser beam to reach the surface. This eliminates the risk for any vaporized material escaping collection because it is being ablated within the fume extraction chamber and everything in this space is under vacuum pressure. The fumes and/or contaminants are then collected through an appropriate method such as series of filters such as HEPA and carbon filters or vented out in an appropriate manner.
The laser output is fired into the fume extraction chamber/devise through a window made of an appropriate material that is transparent and does not absorb the wavelength or wavelengths of the laser output. Example laser output can include a laser beam that is pulsed, modulated, or continuous wave and is directed at a surface with optics to one specific area or spot, and/or is directed to a surface with a scanning mechanism to create a scan pattern on that surface.
An example of window material is fused silica, quartz, a polymer such as acrylic, or other optical glass or transparent material. This window could also have an anti-reflective coating for the laser wavelength/s being used. This window could be made to be easily replaceable in case it gets dirty or damaged.
The fume extraction device can be fixed or portable, be directly integrated and attached/connected to the laser scanner, or function as an independent device that can be either operated by hand or an automated process.
The chamber/device is connected to a vacuum hose or conduit or vacuum source directly. Air is allowed to enter the chamber/device through one or more ports/openings that allow air to flow through the system and create a current that moves vaporized material in the desired direction toward collection (e.g, towards an outlet or output port). The surface of the fume extraction system contacts the surface being laser cleaned directly to create a seal against the surface. There can be a rubber liner, gasket, or other appropriate material to help create this seal. Any surface imperfections that do not allow for a perfect seal do not pose a problem to the collection of the vaporized material, as the vacuum of the system will create negative pressure allowing air to only enter and not exit through those gaps. For example, if there were 100 small imperfections in the surface that create gaps in the seal that allow air to pass through, those 100 imperfection areas would act as 50 small inlet vents that only allow air to enter the chamber and not exit due to the negative vacuum pressure inside.
In the case of working with hazardous materials, the fume capture chamber is the only item that gets contaminated during the laser cleaning process and can be easily replaced with a new one. This would be an extremely cost-effective alternative to replacing all or part of a laser cleaning system.
The present disclosure pertains to fume capture systems that enclose a workspace where a laser is being used to ablate a target surface.
The laser output 108 can include any radiation pattern emitted by any laser scanner. Example include laser scanners but are not limited to galvanometer scanners, piezoelectric scanners, polygon scanners, moving or rotating prism-based scanners, rotating optic scanners, circular scanners, and other conventional optical scanning systems that are used to create a pattern with a laser beam for the purpose of ablation or material processing.
In
The housing 104 can be constructed from any desired material such as metal or plastic, as would be known to one of ordinary skill in the art. The housing 104 is a partial enclosure that is created by a top surface 104A and sides, such as side 104B. The sides define an opening of the enclosure. Thus, the housing 104 is a box that is open on its lower end, where the edges of the sides can contact the target surface 110.
The system 100 can include a window 112 that is constructed from a transparent or at least partially transparent material. The optical attributes of the window 112 can be tuned to the wavelength of the laser scanning system 102, in some embodiments. The window material can be tuned to the wavelength of the laser to prevent any alteration of the laser radiation that would reduce its ablation efficacy. Thus, the laser output can travel through the window 112 without being impeded by the window 112. The window 112 can be made from glass, optical glass, fused silica, quartz, and polymers—just to name a few.
In one embodiment, the window 112 can include an optic, such as a lens that is configured to act as a focus (or other optical enhancement) for the laser scanning system 102. While the window 112 is illustrated on the top surface of the housing 104, the window 112 can be placed on any other surface of the housing 104. In some instances, multiple windows can be placed on one or more of the surfaces of the housing 104. As illustrated and described infra, the housing 104 can be entirely or partially constructed from transparent materials.
In some instances, the window 112 can be removed leaving an opening. The airflow through the housing 104 can be adjusted by changing the operational parameters of the vacuum 106. The airflow can be controlled to reduce a likelihood that contaminants can escape the housing 104 through the opening during ablation. For example, the location, shape, and/or profile of a port or vent of the housing 104 can affect how air and contaminants are drawn away from the opening. Additional details regarding the port or vent are provided in greater detail below.
In various embodiments, the housing 104 comprises at least one port or vent 114 that allows air to enter the housing 104 and create a pattern of airflow. The airflow can be tuned not only to direct the fumes and contaminants out of the housing 104 but also to prevent contamination of the window 112. In one example, the vent 114 is an inlet port in the form of an adjustable opening. The vent 114 can comprise a louver or cover that can be adjusted to control the size of the cross-section of the opening and thus change the amount/velocity of airflow entering the housing. An example adjustable opening is also illustrated in the embodiment of
In some instances, the dimensions of the vent 114 can be selected to create negative air pressure inside the housing 104, which creates suction between the lower edge of the housing 104 and the target surface 110 when air is drawn by the vacuum 106.
In instances where the target surface 110 is porous, air may be drawn in through the small spaces between the lower edge of the housing 104 and the target surface 110. It will be understood that the airflow pressure created by the vacuum 106 can be adjusted to ensure the proper degree of suction between the housing 104 and the target surface 110. For example, the vacuum 106 can be adjusted to ensure that negative pressure is present inside the housing 104. The negative pressure, if sufficient, can allow the housing to stay in place on the target surface 110 without the user having to hold the housing 104 against the target surface 110. In some instances, the vacuum 106 can couple the system 100 with a sequestration system 120 that can store ablation contaminants for disposal or other treatment.
Lower edges of the sides of the housing 104 can be lined with a gasket or seal 116 (see
The inert gas can reduce ignition and fire that may result from the ignition of volatile chemicals produced during the ablation process. As noted above, when the flow of air out of the system 300 through the outlet conduit 306 is greater than the flow of air into the system 300 through the inlet conduit 304, negative pressure is created inside the housing 302, which allows the housing 302 to attach to a work surface.
The use of this system with or without an inert gas can reduce the risk of fires or explosions in environments where there are flammable or combustible materials present in the environment or air.
Advantageously, the system 300 can capture and collect flammable gases created by laser ablation or laser processing. The system 300 can also contain laser-plasma into a confined area when cleaning in environments that may have explosive or flammable gasses ambiently present (such as in an oil refinery). This helps make the laser ablation process explosion-proof. The addition of an inert gas further reduces ignition potential. While nitrogen and argon have may be utilized, any suitable inert gas can be used. In some embodiments, the inert gas may be used to mix with air or to fully replace air with an inert gas purge. Thus, the inert gas reservoir 310 can mix air into the inert gas. In another embodiment, the inlet conduit 304 could include an air intake member such as a vent or valve that allows air to enter the inlet conduit 304 and mix. In yet another embodiment, a vent in the housing 302 can also draw in air through a one-way valve or other mechanisms.
In general, the various ports are either always open or open when the system is under vacuum. The location of these ports can be strategically positioned to optimize the path of airflow within the chamber to make sure collection is efficient and this can also serve the added benefit of causing clean incoming air to blow against the inside face window to help keep it clean.
As with the first and second ports 404 and 406, lips/fins/flaps help direct the flow of air into the chamber in a more linear and/or laminar way. This can be a bent piece of metal or flap inside the chamber. One or more of these ports can be used as needed.
The second port 404 is positioned adjacently to a window 414 of the housing 402. An angled ledge 416 directs air into the housing 402. The air is directed by the angled ledge 416 across a lower portion of the window 414 to prevent ablation contaminants from contacting the window 414 and to cool the window 414. Contaminate buildup on the window 414 may reduce the transparency of the window over time, which would lead to poor ablation. An angled surface 418 of the housing 402 may direct the air flowing underneath the window 414 to circulate towards the lower surface 412. The third port 408 aligns with the window 414 and allows a laser to contact a work surface 418.
The length of the tubular port 804 can vary according to design requirements. The tubular port 804 is utilized in lieu of a window, although a window can be included. The tubular port 804 functions as a funnel and may prevent ablation contaminants from escaping the housing 802. Because the tubular port 804 may not be covered by a window, air can enter the tubular port 804 and travel into the housing 802. The movement of the air downwardly through the tubular port 804 prevents contaminants from moving upwardly through the tubular port 804. A laser scanner 806 can direct a laser beam 808 through the tubular port 804 as illustrated in
In some embodiments, a plurality of fume extracting systems can be connected in series (such as a daisy-chain) to one another or in an array. The interconnected fume extracting systems can be connected to a single vacuum or pump to facilitate airflow through the fume extracting systems.
While some embodiments have contemplated use in various industrial applications, fume capture systems of the present disclosure can be applied in medical applications. For example, vaporized human or organic material can be sequestered and removed during a laser treatment. For example, a laser can be used to remove a growth from a patient's skin or to remove a tattoo with a tattoo removal laser. Thus, the fume capturing systems disclosed herein can also capture organic-based fumes and airborne materials created during laser medical procedures and laser skin treatments.
The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present technology has been presented for purposes of illustration and description but is not intended to be exhaustive or limited to the present technology in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the present technology. Exemplary embodiments were chosen and described in order to best explain the principles of the present technology and its practical application and to enable others of ordinary skill in the art to understand the present technology for various embodiments with various modifications as are suited to the particular use contemplated.
If any disclosures are incorporated herein by reference and such incorporated disclosures conflict in part and/or in whole with the present disclosure, then to the extent of conflict, and/or broader disclosure, and/or broader definition of terms, the present disclosure controls. If such incorporated disclosures conflict in part and/or in whole with one another, then to the extent of conflict, the later-dated disclosure controls.
The terminology used herein can imply direct or indirect, full or partial, temporary or permanent, immediate or delayed, synchronous or asynchronous, action or inaction. For example, when an element is referred to as being “on,” “connected” or “coupled” to another element, then the element can be directly on, connected or coupled to the other element and/or intervening elements may be present, including indirect and/or direct variants. In contrast, when an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present.
Although the terms first, second, etc. may be used herein to describe various elements, components, regions, layers, and/or sections, these elements, components, regions, layers, and/or sections should not necessarily be limited by such terms. These terms are only used to distinguish one element, component, region, layer, or section from another element, component, region, layer, or a section. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer, or section without departing from the teachings of the present disclosure.
The terminology used herein is to describe particular or example embodiments only and is not intended to be necessarily limiting of the disclosure. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “includes” and/or “comprising,” “including” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
Example embodiments of the present disclosure are described herein with reference to illustrations of idealized embodiments (and intermediate structures) of the present disclosure. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, the example embodiments of the present disclosure should not be construed as necessarily limited to the particular shapes of regions illustrated herein, but are to include deviations in shapes that result, for example, from manufacturing.
Aspects of the present technology are described above with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the present technology. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general-purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
In this description, for purposes of explanation and not limitation, specific details are set forth, such as particular embodiments, procedures, techniques, etc. in order to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that the present invention may be practiced in other embodiments that depart from these specific details.
Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” or “according to one embodiment” (or other phrases having similar import) at various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Furthermore, depending on the context of discussion herein, a singular term may include its plural forms and a plural term may include its singular form. Similarly, a hyphenated term (e.g., “on-demand”) may be occasionally interchangeably used with its non-hyphenated version (e.g., “on demand”), a capitalized entry (e.g., “Software”) may be interchangeably used with its non-capitalized version (e.g., “software”), a plural term may be indicated with or without an apostrophe (e.g., PE's or PEs), and an italicized term (e.g., “N+1”) may be interchangeably used with its non-italicized version (e.g., “N+1”). Such occasional interchangeable uses shall not be considered inconsistent with each other.
Also, some embodiments may be described in terms of “means for” performing a task or set of tasks. It will be understood that a “means for” may be expressed herein in terms of a structure, such as a processor, a memory, and I/O device such as a camera, or combinations thereof. Alternatively, the “means for” may include an algorithm that is descriptive of a function or method step, while in yet other embodiments the “means for” is expressed in terms of a mathematical formula, prose, or as a flow chart or signal diagram.
This application claims the benefit and priority of U.S. Provisional Application Ser. No. 63/027,785, filed on May 20, 2020, which is hereby incorporated by reference herein in its entirety, including all references and appendices cited therein, for all purposes, as if fully set forth herein.
| Number | Date | Country | |
|---|---|---|---|
| 63027785 | May 2020 | US |
