System and method for attaching adhesive fasteners

Abstract

The laser ablation containment system includes a laser chamber integrated with a Class 1M or higher-rated laser, and a cleaning chamber coupled to and aligned with the laser chamber for selectively receiving the beam generated by the Class 1M or higher-rated laser. The cleaning chamber includes a header, which is selectively movable between a first position that exposes the interior of the cleaning chamber for placing a substrate inside the cleaning chamber, and a second position that securely closes the interior of the cleaning chamber. In the second position, the header works in cooperation with the laser chamber to form an enclosure capable of operating a Class 1-rated laser.

Description

Technical Field

[0001] The present invention generally relates to systems and methods for the attachment of adhesive fasteners. Generally, the systems and methods for the attachment of adhesive fasteners disclosed herein are designed to prepare the fastener and / or substrate for adhesion, apply an adhesive to the fastener, and / or attach the fastener to the substrate / subassembly with high-quality adhesion.

Background Art

[0002] Surface treatment is an important step in achieving durable adhesion of an adhesive to a substrate, as the effectiveness of the adhesive depends greatly on the quality or degree of cleaning of the surface treatment of the substrate. Conventional methods of surface treatment of substrates typically involve manual polishing of the substrate or surface using abrasives designed to remove oxide layers and contaminant layers deposited on the substrate, such as sandpaper, grinders, or polishing pads. Alternatively, chemicals such as acetone can be used to manually rub the surface to chemically break down unwanted particles from the substrate to remove debris and paint. Manual processes are relatively laborious and time-consuming and tend to result in messy and / or inconsistent results in the surface or substrate being treated due to inconsistencies associated with the abrasives used and human application.

[0003] Furthermore, while more highly automated technologies, such as abrasive grit blasting and / or solvent blasting chemical processes, can be more efficient, they tend to generate a considerable amount of waste because the ablation material (e.g., substrate abrasive material such as grit and / or solvent) and the ablated foreign matter from the substrate mix together, generally creating a source of secondary waste and / or chemicals that are harmful to humans and the environment. Environmental regulations have been introduced to limit the use of hazardous chemicals, and due to the high cost of waste disposal, minimizing the amount of secondary waste generated during contaminant removal is a priority. Moreover, these manual techniques are also labor-intensive and time-consuming processes, and again, human intervention leads to variations in the degree of uniformity across the treated substrate and surface.

[0004] More recent laser ablation processes are generally considered an enhancement to the mechanical and / or chemical removal processes described above. In this regard, laser ablation is a process that uses a high-intensity laser beam irradiated onto a substrate to remove surface material and debris. The laser generates a focused beam with sufficient power density to be absorbed by the substrate, generating a plasma plume and shock waves that effectively destroy, remove, and discharge foreign matter adhered or otherwise attached to the substrate as debris into the surrounding environment. Most laser-based processes are automated, saving on manual labor costs compared to the manual sandpaper or grit blasting processes described above. Furthermore, laser-based ablation produces less waste because it does not use mechanical abrasive grit or potentially harmful chemicals to remove foreign matter from the substrate. In this way, laser ablation processes help minimize their environmental impact by reducing the amount of secondary waste generated.

[0005] In one prior art document, Patent Document 1 (U.S. Patent No. 5,780,806 granted to Ferguson) (the entire contents of which are incorporated herein by reference), a laser ablation system and a method for decontaminating a surface using the same are disclosed. More specifically, Ferguson discloses a laser ablation system comprising a laser, a flexible optical fiber cable optically coupled to the laser for transmitting laser light for ablation or decontamination of a surface, and an output optical system assembly including a nozzle through which the laser light passes. The assembly further includes an exhaust tube substantially in communication with the nozzle and a blower for generating a vacuum in the exhaust tube. When in operation, the laser ablation system generates acousto-optic Q-switched Nd:YAG laser light to ablate foreign matter from a substrate, 1 x 10⁻¹⁶ 7 W / cm 2 It generates irradiances exceeding [a certain level] and pulse widths between 80 and 170 nanoseconds (ns). Ablating the substrate surface with such irradiance is usually effective in removing debris from the substrate, which is then removed by a vacuum evacuation tube. However, Ferguson does not appear to include an air knife or curtain to protect the laser protective cover, or a structure that allows for easy replacement of the protective cover after extensive use.

[0006] Furthermore, the National Robotics Center (NREC) at Carnegie Mellon University in Pittsburgh, Pennsylvania, in collaboration with Concurrent Technologies Corporation (CTC) in Johnstown, Pennsylvania, has jointly developed the Advanced Robotic Laser Coating Removal System (ARLCRS) for removing coatings and debris from U.S. Air Force aircraft. More specifically, the ARLCRS system includes a commercially available laser integrated with a scanner and a particle capture system integrated and mounted on a mobile robot base and surface monitoring sensors. A robotic arm scans the aircraft's surface for debris and paint to be removed, and uses a powerful laser to ablate the substrate and remove the paint and coating from the aircraft. This allows a team of robots equipped with debris and paint removal lasers to work together synchronously to remove paint and coating from aircraft. ARLCRS is an automated and improved version of a handheld infrared laser device (e.g., at a wavelength of 1064 nanometers ("nm")) and can also be used to manually remove rust or paint / primer from larger surfaces such as aircraft fuselages and shipyard vessels. The problem with these systems is the lack of containment (storage) of the emitted laser light. Therefore, although the amount of waste generated is less than with grid or chemical-based solutions, potentially harmful laser light still exists on and / or around the ablated surface, and the workspace environment must meet higher class (e.g., Class 1M or higher) laser safety standards. Because workers may be exposed to the laser beam without proper safety measures, it is crucial to follow laser safety protocols and wear protective eyewear. ARLCRS are ideally used in dedicated laser processing rooms, which are generally considered impractical due to their high manufacturing costs and the fact that ARLCRS are relatively large vehicle structures (e.g., aircraft) designed for ablation.

[0007] In this case, generally known laser ablation processes have drawbacks, primarily related to the fact that no Class 1 laser ablation enclosure system is known for removing debris from the substrate, much less is it transportable or easily deployable in existing manufacturing environments. Consequently, the laser ablation process must be carried out in a special room constructed to comply with current safety standards for operating higher-class lasers, including the requirement that operators in the room wear protective gear and / or other special glasses. Performing the ablation process in these rooms is particularly unsuitable for implementing the laser ablation process as an existing step in a manufacturing process (e.g., an existing assembly plant) or an existing repair facility. At the very least, for example, the substrate to be ablated must be moved between rooms with appropriate built-in safety mechanisms as part of the manufacturing process. This can result in delays and unnecessarily increase costs associated with cleaning the substrate before applying, for example, adhesive-backed nut plates.

[0008] Another issue in the aerospace industry concerns the process of automating the micro-dispensing of adhesives for relatively small quantities, such as the aforementioned nut plates. Micro-dispensing techniques, as known in this field, produce or dispense liquid media in relatively small injection volumes, such as on the order of less than 0.1 grams (g). Dispensing adhesives, liquids, oils, greases, and / or other viscous media is particularly challenging to achieve with high reliability and accuracy at such small volumes. Precise positioning and fluid volume, reagents, and cycle time have a significant impact on the overall quality of the dispensed adhesive, particularly in terms of the ability to consistently and reproducibly control the dispensed volume and location of the adhesive being applied. The ability to control these relatively small amounts of adhesive (i.e., on the order of <0.1g) becomes critical when applied to relatively small parts such as nut plates that can be used in aerospace applications.

[0009] In one prior art device, Patent Document 2 (U.S. Patent No. 9,931,665 granted to Cheung) (the entire contents of which are incorporated herein by reference) discloses a liquid compound dispensing device for dispensing a controlled amount of liquid compound onto a workpiece. More specifically, Cheung discloses a cartridge system for selectively receiving and holding a cartridge containing a liquid compound. A plate with threaded holes is positioned above the cartridge system and coupled to one end of a plunger, and a piston is coupled to the other end of the plunger. The piston is sized and shaped to move within the liquid-containing cartridge and replace the liquid compound from it. When in operation, a drive system operates, moving the plate to which the plunger and piston are attached forward to dispensing the liquid from the cartridge, and stopping the piston when dispensing stops. The cartridge can then be removed and replaced when its contents are depleted. As with known prior art designs, the dispensing speed of the liquid compound is controlled by the speed at which a motor drives the system to displace the piston within the cartridge.

[0010] In another design, Patent Document 3 (U.S. Patent No. 8,469,231 granted to Strecker) (the entire contents of which are incorporated herein by reference) describes a volume of 1 cubic millimeter (mm 3A dispensing system for dispensing amounts less than ) is disclosed. More specifically, Strecker discloses a housing having a pair of liquid holding vessels, the housing being fluid-coupled to each of a pair of input channels that selectively guide liquid from the holding vessels to first and second feed screws, respectively. The liquid compound in each of the holding vessels is dispensed into the input channels by a pair of pistons, which are designed to be driven or pushed into the holding vessels to drive the liquid compound inside out through the input channels. The pistons provide back pressure that moves the liquid compound out of each of the liquid holding vessels and into the pair of input channels to eventually come into contact with the pair of feed screws. The dispensing is then driven by acting on feed screws, which are located in a chamber and have helical threads that mix the compound flowing in as it rotates. As rotation continues, the mixed liquid compound is dispensed through the dispensing tip. However, Strecker does not disclose any feedback sensors for monitoring the amount or quality of liquid being dispensed from the tip, nor does it appear to disclose that, since the dispensed liquid has already flowed out of each input channel and is primarily driven by the rotation of the feed screw, the piston can be moved out of the liquid-holding container by air pressure to stop any subsequent "leakage" or "dripping."

[0011] In another prior art document, Patent Document 4 (U.S. Patent No. 8,578,729 granted to Fiske) (the entire contents of which are incorporated herein by reference) discloses a system for dispensing relatively small amounts of viscous material onto a workpiece using a dispenser with a relatively narrow profile. More specifically, the dispenser disclosed by Fiske comprises a fluid chamber, a nozzle, and a valve seat disc having individual components, each of which is removable from the dispenser body for cleaning and / or replacement. The viscous material is supplied under pressure from a supply container through a fluid tube to an inlet port and dispensed through the nozzle.

[0012] The problems with adhesive dispensing systems known to use this technology, as described above, are that it is difficult to consistently and reliably dispense relatively small amounts of liquid under pressure using a pneumatic system that applies constant pressure to a piston located at the rear of the liquid compound in the cartridge container. This is because pneumatic systems require a valve to "start" and / or "stop" the flow of adhesive. The physical position of the valve is usually in the flow of adhesive and therefore in constant contact with it. Such "wet" valves are exposed to the adhesive in a certain curing state and do not particularly help to prevent "leakage" or "dripping" after the dispensing is supposed to have completely stopped. Furthermore, known pneumatic systems do not include a "pullback" function to control the flow of adhesive, which is considered incompatible with pneumatic systems in the first place due to the inherent limitations of the aforementioned pneumatic function. [Prior art documents] [Patent Documents]

[0013] [Patent Document 1] U.S. Patent No. 5,780,806 [Patent Document 2] U.S. Patent No. 9,931,665 [Patent Document 3] U.S. Patent No. 8,469,231 [Patent Document 4] U.S. Patent No. 8,578,729

[0014] Therefore, there is a significant need in this technology for a system and method for attaching adhesive fasteners that is designed to prepare fasteners and substrates in order to apply adhesive to fasteners at a consistent rate without "leakage" or "dripping" for bonding by laser ablation using a Class 1 laser enclosure having an integrated air curtain or knife and vacuum exhaust system, and to attach fasteners to substrates / partial assemblies with high-quality adhesion. The present invention satisfies these requirements and provides further relevant advantages. [Overview of the project]

[0015] In one embodiment disclosed herein, the laser ablation storage system may include, integrated as part of a transportable roller station, a laser chamber having a Class 1M or higher-rated laser (e.g., a Class 4 laser), and a cleaning chamber coupled to and aligned with the laser chamber for selectively receiving the beam generated by the Class 1M or higher-rated laser. The cleaning chamber includes a header which is selectively movable between a first position that exposes the interior of the cleaning chamber and a second position that securely closes the interior of the cleaning chamber for placing a substrate into the cleaning chamber, and in the second position, in cooperation with the laser chamber, forms an enclosure capable of operating a Class 1-rated laser.

[0016] The cleaning chamber and laser chamber may be coupled to a robotic arm, which is movable to selectively position the header facing the substrate to form an enclosure containing the cleaning chamber and laser chamber. The robotic system may also include a gripper having a pair of actuating fingers, which is positioned below the umbrella portion and is actuated to selectively pick and place the substrate within the enclosure formed by the sealing engagement between the umbrella portion and the seal rim. Here, the robotic system selectively positions an elastomer fixture protruding downward from a nut plate to seat onto a bracket, which protrudes inward from the inner side wall of the cleaning chamber, forming a gap between the bracket and the inner side wall of the cleaning chamber.

[0017] In one embodiment, the umbrella portion may be slidable along an axis perpendicular to the focusing lens of a laser rated Class 1M or higher and mounted in the laser chamber. In another embodiment, a proximity sensor may be positioned to identify when the umbrella portion is seated on the seal rim in order to ensure that the laser ablation housing system continues to operate the Class 1 certified enclosure with a Class 1M or higher rated laser. In these embodiments, the header includes a compressible liner projecting outward, the liner may form at least a portion of the outer perimeter of the enclosure, and at least one sensor may be positioned to measure pressure or light within the enclosure.

[0018] In another aspect of these embodiments, the cleaning chamber of the laser ablation storage system may be in fluid communication with the debris removal chamber. Furthermore, a selectively removable and replaceable protective lens may be selectively positioned within a slot to substantially seal the laser chamber from the cleaning chamber in order to further protect a Class 1M or higher-rated laser. Here, the protective lens may be held by a protective lens holder and may have a forward channel that provides access to the protective lens when removing it from the slot. However, the forward channel is positioned coplanar with the inner sidewall of the cleaning chamber when the protective lens is inserted into the slot, thereby locking the protective lens within the protective lens holder.

[0019] Furthermore, the header may include a clamp having a base, the base having a lower sealing member extending upward from the base, the lower sealing member cooperating with the upper sealing member when the header is in a second position to form an enclosure between the lower sealing member and the upper sealing member. Here, the lower sealing member may be made of foam or rubber material and is movable by a linear actuator or pneumatic piston relative to the upper sealing member, which may also be made of foam or rubber material.

[0020] In another aspect of these embodiments, the laser chamber may be offset from the cleaning chamber by an angle between 90 and 180 degrees. In an additional example or variation, a mirror or prism located within one of the laser chamber or cleaning chamber may be positioned to receive the beam and redirect it again with an angle of up to 180 degrees. Here, at least one of the mirror or prism is mounted on a pivot (e.g., a single-plane pivot, a multi-plane pivot, or a ball-socket pivot) and is repositionable in real time within one of the laser chamber or cleaning chamber.

[0021] In another embodiment, the debris containment system disclosed herein includes a conduit for delivering pressurized fluid to a cleaning chamber and an outlet coupled to the conduit, the outlet positioned to direct the pressurized fluid substantially across the internal channel of the cleaning chamber as an air curtain substantially across the internal channel of the cleaning chamber, substantially preventing debris on one side of the internal channel of the cleaning chamber from crossing the air curtain to the other side of the internal channel of the cleaning chamber. In this case, the air curtain may extend substantially horizontally toward a debris removal chamber that crosses the internal channel and is in fluid communication with the internal channel. The outlet may also include a substantially elongated slot, the elongated slot formed in a tubular bracket extending through the internal channel of the cleaning chamber, and / or the outlet may be positioned at a certain angle to the internal channel, and the air curtain may extend at a certain angle to the internal channel to cross the internal channel.

[0022] More specifically, the internal channel may be a cylindrical channel, and the outlet may be a hemispherical slot formed in the internal side wall of the cleaning chamber. Here, the hemispherical slot faces forward of the internal channel, and the air curtain may extend substantially horizontally toward the debris removal chamber so as to cross the internal channel of the cleaning chamber. In this case, the elongated slot may be positioned so that the air curtain flows at least partially vertically through the internal channel of the cleaning chamber, in opposition to the movement of debris toward the laser chamber coupled to the cleaning chamber.

[0023] In another embodiment, the conduit may include a first conduit and a second conduit, and the outlet may include a first outlet and a second outlet. Here, each of the first outlet and the second outlet may open into an internal channel, and the internal channel may generate a first air curtain and a second air curtain offset from the first curtain. More specifically, the first conduit may include an upper conduit, the second conduit may include a lower conduit, and each of the upper conduit and the lower conduit may include respective slots, and the slots may have a width of about half the outer circumference of the internal channel of the cleaning chamber. In this embodiment, both the first air curtain and the second air curtain may extend substantially across the internal channel of the cleaning chamber and at the same angle or different angles with respect to each other. An air pressure sensor is positioned within one of the cleaning chamber or the debris removal chamber to ensure that there is an appropriate pressure and air flow within the cleaning chamber and / or the debris removal chamber. In this regard, at least one of a HEPA filter or a carbon filter may be positioned within the debris removal chamber that absorbs debris discharged from the cleaning chamber.

[0024] In another embodiment disclosed herein, the adhesive dispenser system may also be integrated with a transportable roller station and includes a frame to which a drive unit is attached and a screw that is screw-operated by the drive unit, the screw engaging a carrier unit slidable relative to the frame and having at least one collet assembly rigidly coupled to the carrier unit. The at least one collet assembly may include a piston collet that is selectively slidably engageable with a piston head and is operable to dispense liquid from a cartridge when the drive unit operates the screw in a first direction and is operable to reduce and / or eliminate "liquid leakage" or "dripping" of the liquid when the drive unit operates the screw in a second direction opposite the first direction. The drive unit may operate the screw to dispense a small amount of liquid of about 0.1 gram (g) at a time.

[0025] The adhesive dispenser system may also include a support bracket having an extension, the extension being sized to receive the dispensing needle in a spaced-apart relationship relative to the frame, the support bracket being selectively adjustable relative to the frame by an elongate channel, the elongate channel being lockable to the frame by positioning pins disposed therein. The adhesive dispenser system may also include at least one feedback sensor coupled to the drive unit (e.g., a force feedback sensor that measures the current or voltage of the drive unit in real time) to provide real-time sensed feedback regarding the viscosity of the adhesive. As a variant, a camera for imaging the adhesive dispensed from the cartridge may be positioned. The flow rate actuated by the drive unit and the screw may be changed based on the force feedback and / or the visual appearance of the adhesive dispensed from the tip. Another feature of these embodiments is that the frame may include a thermal enclosure, the thermal enclosure having a cooling or heating element proximate to the quick-change carrier for temperature-regulating one or more fluids within the cartridge in real time.

[0026] In another aspect of these embodiments, at least one collet assembly may include a pair of collet assemblies, each of the pair of collet assemblies including a respective piston collet, the piston collet being selectively slidably engaged with a respective piston head operable to dispense adhesive from the dual cartridge assembly. Here, the respective piston heads may have different sizes relative to each other depending on the liquid required to produce the adhesive and accommodated in the dual cartridge assembly. Additionally, the piston collet may terminate in an outer flare mandrel, the mandrel being sized to frictionally engage the piston head.

[0027] The liquid cartridge may be removed for replacement after it has been used up by a one-step quick-release mechanism that disengages the piston collet from the cartridge. Here, the quick-release mechanism may include a slide bracket having a stepped portion, which is actuated to compress a spring from a first normal extended position to a second compressed position that pulls the piston collet away from engagement with the piston head. The slide bracket may include a pull-back channel having a slide pin, which may restrict the movement of the slide bracket relative to the carrier unit to a predetermined distance. In a variation, instead of or in addition to the pull-back channel, a stop coupled to the carrier unit may be positioned to restrict the rearward movement of the slide bracket relative to the carrier unit to a predetermined distance.

[0028] In another embodiment, the quick-change cartridge system includes a frame and a liquid storage cartridge, the frame including a pair of outwardly extending locator pins having a size and shape for selective sliding fit engagement with a slotted housing of a dispenser unit, the liquid storage cartridge having a size and shape for selective sliding reception into and / or removal from the opening of the frame when the frame is removed from the dispenser unit, and the liquid storage chamber being positionable in a forward position within the frame, in fluid communication with a dispensing outlet when the frame engages with the dispenser unit.

[0029] The frame includes a front hole, which may be smaller in size and shape than the liquid storage cartridge but larger than the dispensing outlet. This allows the liquid storage cartridge to be selectively slidably received into and / or slidably removed from the frame. Furthermore, the frame's locator pin includes an outwardly extending bolt, which may have a shank portion that is long and smooth enough for slidable reception into the slotted housing in order to position the bolt head portion outside the slotted housing. The slotted housing includes a pair of externally accessible L-shaped receiving channels, which may be wider than the width of the shank portion and narrower than the width of the bolt head portion. In this regard, the externally accessible L-shaped receiving channels may include an enlarged chamfered opening upper portion accessible for drop-in reception of the frame of the slotted housing by the locator pin.

[0030] In another aspect of these embodiments, the liquid storage cartridge includes an outwardly extending base plate, which may be at least partially larger than the opening for coplanar engagement with the frame when the liquid storage cartridge is mounted to the frame. Furthermore, the liquid storage cartridge includes a pair of liquid storage cartridges, each of which is in fluid communication with a cap having an outlet port, and the outlet port may be selectively coupled to a dispensing outlet including an inlet for a static mixer extending outward from the frame. The liquid storage cartridge also includes at least one rear receiving slot, which may be sized and shaped for selective engagement with a collet assembly of a dispenser unit.

[0031] The adhesive dispensing feedback method disclosed herein may include the steps of: operating a drive unit for dispensing a certain amount of adhesive at a desired flow rate; monitoring one or more dispensing characteristics associated with the amount of adhesive being dispensed; cross-referencing one or more dispensing characteristics with a set of operating parameters for each of the one or more dispensing characteristics; and, if one or more dispensing characteristics deviate from any of the set of operating parameters, using the drive unit to adjust the desired flow rate of the amount of adhesive.

[0032] More specifically, a carrier unit having a pair of collet assemblies is initially slid to engage with each of a pair of cartridges positioned in a stationary relationship with the carrier unit. Here, a pair of piston collets on each collet assembly may be friction-fitted to the respective piston heads in a fluid relationship with each of the cartridges. When the screw is rotated in a first direction that causes the collet assemblies to move forward, liquid is dispensed from each of the cartridges into a static mixer for forming an adhesive, and finally delivered to the outlet tip. When dispensing is to stop, the drive unit may reverse the screw in a second direction to pull the piston heads in the liquid storage cartridges back by the collet assemblies. This may create a negative pressure at the outlet tip, pulling back excess adhesive and thereby effectively stopping "leakage" or "dripping" from the outlet tip.

[0033] In another aspect of these embodiments, the monitoring step may further include sensing the viscosity of the adhesive being dispensed and determining whether the viscosity is below or above a threshold; sensing the current or voltage of the drive unit in real time and determining whether the current or voltage is below or above a threshold; measuring the ambient temperature or the temperature of the adhesive; measuring one or more dispensing characteristics in real time or in discrete time increments; and / or observing the adhesive with a camera. Reading the temperature of one or more liquid compounds in the liquid dispensing cartridge may help to adjust the quality and quantity of the adhesive being dispensed in real time. Such adjustment may include changing the temperature of one or more liquid compounds in the liquid dispensing cartridge with a heater or cooler, for example, to help control the viscosity of the adhesive. Accordingly, the adjusting step may include changing the rotational speed of a screw that is operated to slide the carrier unit by the drive unit.

[0034] In another embodiment, the selectively removable and / or interchangeable protective lens holder disclosed herein includes a frame having a forward-positioned receiving channel, the size and shape of which the receiving channel is configured to selectively receive a protective lens (e.g., light-transmitting) into the receiving channel when the frame is in a first open position, and to move to a second position to lock the protective lens in cooperation with the inner sidewall when slidably engaged with the inner sidewall of the cleaning chamber. The receiving channel may include a substantially horizontal open slot for selectively inserting and removing a protective lens into the receiving channel when in the first open position.

[0035] In addition, the protective lens holder may include a handle, which extends outward from the frame away from the receiving channel, and the size and shape of the handle are configured to allow manual operation outside the outer side wall of the cleaning chamber. Here, the handle includes a pair of arcuate recesses facing opposite directions, which improve manual operation of the protective lens holder outside the outer side wall of the cleaning chamber.

[0036] In another embodiment, the debris removal system includes an outlet conduit, which is in fluid communication with a cleaning chamber, and the debris removed from the substrate is located in the cleaning chamber. The port of the outlet conduit may be coupled to and in fluid communication with a pressure sensor to measure the pressure in the outlet conduit in real time, and a controller may be coupled to the pressure sensor and communicate with a laser that is operable to generate a beam into the cleaning chamber to remove debris from the substrate. Here, the controller is operable to deactivate the beam in response to the pressure loss in the outlet conduit measured by the pressure sensor. Furthermore, the inlet port may selectively accept a pressurized fluid that generates at least a partial vacuum in the outlet conduit relative to the cleaning chamber, and the inlet port may be coupled to a pneumatic air pump. Also, a HEPA filter or carbon filter may be positioned in the outlet conduit to filter the debris.

[0037] In another embodiment, the process (method) for replacing a quick-change cartridge includes sliding the carrier to disengage it from the frame of the dispensing unit, removing the liquid storage cartridge from the carrier through an access port, inserting a new liquid storage cartridge through the access port, and reinserting the carrier supporting the new liquid storage cartridge into the frame of the dispensing unit. This process may further include moving a pair of locking pins, which protrude outward from the carrier through an L-shaped channel formed in the frame and accessible from the outside. Here, the outwardly protruding pair of locking pins may be bolts, which have a shank portion that is movable within the L-shaped channel and a head portion that is larger than the L-shaped channel and positioned outside the L-shaped channel. In this case, in one embodiment, when the carrier is reinserted into the frame, the new liquid storage cartridge may be locked in the front slot of the L-shaped channel.

[0038] The process may further include a step of disengaging the liquid storage cartridge from its engagement with the slide unit. In this case, this may be done by moving an externally accessible slide bracket rearward relative to the slide unit, compressing a tension spring, normally positioned forward, within a retraction channel by engaging a washer located at one end of the tension spring and an inwardly protruding step, and disengaging and retracting the flaring mandrel of the piston collet from its friction fit engagement with the piston head associated with the liquid storage cartridge in response to the compression of the tension spring. Here, the compression step may include compressing the tension spring using an intermediate protruding step positioned between the coils of the tension spring, and the moving step may include ending the rearward movement of the slide bracket using a stop integrated with the frame or a stop positioned within a retraction channel formed in the slide bracket. Once a new liquid storage cartridge is engaged with the frame, the reinsertion step involves re-engaging the slide unit with the piston head associated with the new liquid storage cartridge by tapping a screw, rotating an externally accessible knob, or retracting the piston head to engage.

[0039] In another process (method) disclosed herein, cleaning the surface of a substrate may include: surrounding a laser chamber incorporating a Class 1M or higher-rated laser; positioning the substrate in an ablation chamber coupled to the laser chamber and aligned with a Class 1M or higher-rated laser; moving a header between a first position exposing the interior of the ablation chamber to position the substrate within the ablation chamber and a second position closing the interior of the ablation chamber and cooperating with the laser chamber to form an operable enclosure for a Class 1-rated laser; generating a beam with the Class 1M or higher-rated laser; and bringing at least a portion of the substrate into contact with the beam to clean debris from the substrate.

[0040] The above process may further include the steps of picking and placing the substrate within the header and sandwiching the substrate between the upper and lower sealing members of the header. Furthermore, the substrate may be positioned at an angle between 90 and 180 degrees relative to the beam, for example by correcting the orientation of at least a portion of the beam with a mirror, so that the contact step may ablate the substrate simultaneously at two different beam angles. In this embodiment, the mirror may be pivoted in real time (for example, around a ball-socket joint) to reposition the angle at which the mirror and beam contact the substrate. In additional examples or modifications, the beam may be split by a prism before contacting the substrate.

[0041] The above process may also include the steps of inserting a protective lens between the laser chamber and the ablation chamber (for example, so that the beam passes through the protective lens into contact with the substrate), and activating a proximity sensor in response to the insertion of the protective lens or the formation of an enclosure capable of operating a Class 1 certified laser. Here, as part of the insertion step, the front slot of the protective lens holder may be brought into contact with the inner side wall so as to lock the protective lens within the protective lens holder.

[0042] The above process may further involve monitoring the Class 1 certified laser-operable enclosure in real time using at least one sensor, and terminating the beam when the enclosure no longer conforms to Class 1 based on real-time feedback from at least one sensor (e.g., a pressure sensor or an optical sensor). Alternatively, the pressure difference between the cleaning chamber and the outlet port may be measured in real time, and the beam may be deactivated when the pressure difference between the cleaning chamber and the outlet port falls below a predetermined threshold. The pressure difference is also important for pressurizing the enclosure to create a vacuum at the outlet port, thereby expelling debris from the cleaning chamber.

[0043] Another process (method) for attaching a fastener to a substrate disclosed herein may include the steps of: cleaning the adhesive surface of the fastener and at least a portion of the substrate with a laser; positioning the cleaned adhesive surface of the fastener near an adhesive dispenser; applying adhesive to the adhesive surface of the fastener using the adhesive dispenser; and bonding the fastener to the substrate along an adhesive line formed between the adhesive surface of the fastener and the substrate. The cleaning step may include operating a Class 1M or higher-rated laser in a Class 1 certified laser enclosure, which is done, for example, by opening an ablation chamber coupled with a Class 1M or higher-rated laser, placing the fastener or substrate in the ablation chamber, and closing the header of the ablation chamber around the fastener or at least a portion of the substrate to be ablated to form a Class 1 certified laser enclosure. In addition, a beam may be generated using the laser and brought into contact with the beam the adhesive surface or at least a portion of the substrate.

[0044] Furthermore, the cleaning step may further include selecting a fastener containing one of several nut plates, positioning the nut plate against an internal bracket projecting inward from the internal side wall of the cleaning chamber such that the elastomer member extending from the bottom surface of the nut plate is bent away from the laser beam path, and ablating the bottom surface of the nut plate with the beam. Here, the ablating step may also include rotating the bottom surface of the nut plate relative to the beam while the elastomer member remains bent away from the beam.

[0045] In addition, the positioning step may include removing the ablated nut plate from the cleaning chamber, sliding the elastomer member into the slot of the locator block, and simultaneously aligning the bottom surface of the nut plate near the outlet of the adhesive dispenser while the elastomer member is bent away from the outlet. Furthermore, the application step may include bending the elastomer fixture away from the outlet and simultaneously rotating the bottom surface of the nut plate relative to the outlet of the adhesive dispenser, the rotating step may include adjusting the rotational speed of the bottom surface of the nut plate in response to a desired flow rate of adhesive, and the bonding step may include pulling the elastomer member through the hole in the substrate to draw the bonding surface of the fastener into the substrate and bond it.

[0046] In another process (method) disclosed herein, a method for containing debris in a cleaning chamber may include the steps of: delivering a pressurized fluid into a debris containment chamber; dispersing the pressurized fluid as an air curtain across an open inner channel of the debris containment chamber; preventing at least some of the debris in the debris containment chamber from crossing the air curtain; and simultaneously discharging at least some of the pressurized fluid, together with at least some of the debris, out of an outlet port fluid-coupled to the debris containment chamber.

[0047] Here, the air curtain includes a pair of air curtains, which may include a first air curtain positioned substantially perpendicular to the inner channel and a second air curtain offset by 10 to 90 degrees from the direction perpendicular to the inner channel. In this case, the dispersing step may include forming the first air curtain outside a slot formed in at least a portion of the open inner channel of the debris containment chamber, or forming the second air curtain outside a tubular bracket extending into the open inner channel of the debris containment chamber. The system may also monitor the real-time pressure inside the debris containment chamber to efficiently and effectively discharge the debris from the debris containment chamber.

[0048] Other features and advantages of the present invention will become apparent from the following more detailed description, in conjunction with the accompanying drawings illustrating the principle of the present invention as an example.

[0049] The attached drawings illustrate the present invention. [Brief explanation of the drawing]

[0050] [Figure 1] This is a perspective view of the entire surrounding laser ablation storage and debris removal system, which is integrated as part of a transport roller station including a SCARA robot and adhesive dispenser. [Figure 2] Figure 1 is an enlarged perspective view of the entire perimeter of square 2, and more specifically, a perspective view showing a Class 4 laser coupled with a laser ablation containment and debris removal system, and an adhesive dispenser integrated with the laser ablation containment and debris removal system. [Figure 3] This is a perspective view showing a fully assembled laser ablation containment and debris removal system in more detail. [Figure 4]Figure 3 is an exploded perspective view of the laser ablation storage and debris removal system, and more specifically, it shows an exploded perspective view of a gripper that can be sealed in the ablation chamber when a Class 4 laser is activated and can be operated by a SCARA robot. [Figure 5] This is an enlarged, full-circumference perspective showing a gripper that holds the nut plate and biases the elastomer fastener away from the dispenser that applies adhesive to the underside of the nut plate. [Figure 6] Figure 3 is a plan view of the laser ablation storage and debris removal system, excluding the upper umbrella section, further showing the ablation chamber housing the V-shaped crossing bracket. [Figure 7] This is a perspective view of the bottom side of the laser ablation storage and debris removal system, further showing a vacuum pressure sensor and an air inlet port that guides pressurized air into the ablation chamber to activate one or more air curtains and direct the debris out of the vacuum chamber. [Figure 8] This is a partial cross-sectional view along line 8-8 in Figure 6, which more specifically shows a protective lens holder that is selectively removable and separates the laser protection chamber from the ablation chamber, and also shows that the vacuum pressure sensor is coupled to the vacuum chamber. [Figure 9] This is an enlarged partial cross-sectional view of circle 9 in Figure 8, further showing a V-shaped cross bracket positioned within the ablation chamber to direct the airflow from the ablation chamber into the vacuum chamber, which is fluid-coupled to the ablation chamber. [Figure 10] Figure 3 is a partial cross-sectional view along line 10-10, and more specifically, a partial cross-sectional view showing the pressurized air channel coupled to the ablation chamber. [Figure 11] Figure 3 is a cross-sectional view along line 11-11, and more specifically, it is a cross-sectional view showing the open port of the vacuum pressure sensor coupled to the vacuum chamber. [Figure 12]Figure 4 is a cross-sectional view along line 12-12, and more specifically, it is a cross-sectional view showing a vacuum pressure sensor coupled to a vacuum chamber and a portion of a pressurized air channel. [Figure 13] Figure 4 is a cross-sectional view along line 13-13, which more specifically shows a pressurized air channel branching into a pair of conduits to direct pressurized air into the ablation chamber to generate a pair of air curtains during use. [Figure 14] This is a cross-sectional view similar to Figure 13, with the laser ablation storage and debris removal system rotated approximately 270 degrees. More specifically, it shows the branching of the pressurized air channel into the lower hemispherical conduit and the upper horizontal conduit. [Figure 15] Figure 4 is a cross-sectional view along line 15-15, and more specifically, it shows a cross-sectional view of the lower hemispherical conduit that sends pressurized air to the hemispherical slit in order to generate a horizontal air curtain across the opening inside the ablation chamber. [Figure 16] Figure 4 is a cross-sectional view along line 16-16, and more specifically, it shows an upper horizontal conduit that directs pressurized air into a vertically oriented horizontal slit of the bracket to generate an air curtain that is at least partially vertical, directing the debris upward and into the vacuum chamber away from the protective lens holder. [Figure 17] This is a perspective view showing in more detail one embodiment of the protective lens holder disclosed herein. [Figure 18] This is a rear perspective view of the adhesive dispenser disclosed herein. [Figure 19] Figure 18 is a partial cutaway plan view of the adhesive dispenser at line 19-19, further showing a pair of cartridges and a pair of collet assemblies engaged forward in a dual cartridge dispensing system. [Figure 20] Figure 19 is an enlarged partial broken plan view at circle 20, further showing that each of a pair of collet assemblies includes a spring-biased slide bracket that is movable to separate the pair of collet assemblies from the pair of cartridges. [Figure 21] This is a rear perspective view showing the quick-change carrier disassembled relative to the adhesive dispenser. [Figure 22] Figure 21 is an enlarged front perspective view of circle 22, and more specifically, a perspective view showing the quick-change carrier engaged with the dual-cartridge interchangeable system. [Figure 23] This is a rear perspective view of the dual cartridge exchangeable system shown in Figures 21 and 22, which engages with the quick-change carrier in a sliding manner. [Figure 24] This is a perspective view of the rear side, similar to Figure 23, showing the sliding removal of the dual cartridge exchangeable system from the quick-change carrier. [Figure 25] Figure 18 is a side view of the adhesive dispenser. [Figure 26] Figure 25 is a cross-sectional view along the approximate line 26-26, further showing the screw threads that engage with the piston slide carrier. [Figure 27] This is a periphery perspective view showing the adhesive applied to the underside of a nut plate by the adhesive dispenser disclosed herein. [Figure 28] This is an enlarged perspective view of one of the collet assemblies, further showing the outward flare mandrel positioned within the flare sleeve that selectively connects to the piston head of a dual-cartridge interchangeable system. [Figure 29] A perspective view of a modified adhesive dispenser, including an externally accessible rotatable knob that is operable to rotate a tapping screw to screw into or loosen one of the piston heads of a dual-cartridge interchangeable system. [Figure 30] This is a perspective view of another adhesive dispenser disclosed herein, including a thermal enclosure housing a dual-cartridge replaceable system. [Figure 31]Figure 30 is a perspective view of a modified adhesive dispenser similar to the one shown in Figure 30, and is a perspective view showing a cooler and a pair of heating elements that temperature-control a dual-cartridge replaceable system within a thermal enclosure. [Figure 32] This is a perspective view of the entire surroundings of a substrate ablation and debris removal system integrated for use as part of a transportable roller station in conjunction with a collaborative robot (cobot). [Figure 33] This is a perspective view of a fully assembled substrate ablation and debris removal system. [Figure 34] This is a perspective view of a modified substrate ablation and debris removal system similar to Figure 33, rotated to show the ablation enclosure and gripper in more detail. [Figure 35] Figure 34 is a partially disassembled perspective view of the substrate ablation and debris removal system. [Figure 36] This is a perimeter perspective view showing the bracket to be ablated on the carrier and the open ablation enclosure aligned with it. [Figure 37] This is a perspective view of the entire perimeter, similar to Figure 36, and further shows an upper sealing member that engages with the upper surface of the carrier in a vacuum sealing relationship to enclose the bracket internally. [Figure 38] This is a perspective view of the entire perimeter, similar to Figures 36 and 37, and further shows the lower sealing member that engages with the bottom surface of the carrier in the vacuum seal relationship. [Figure 39] Figure 33 is a cross-sectional view along lines 39-39, more specifically showing the ablation enclosure and the fluid-coupled fume extractor. [Figure 40] Figure 34 is a partial cross-sectional view along line 40-40, and more specifically, it is a cross-sectional view showing the fume extractor, the fluid-coupled air pressure sensor and its open port. [Figure 41]Figure 33 is a partial cross-sectional view along line 41-41, which more specifically shows a protective lens holder that is in fluid communication with the fume extractor and is positioned between the laser protection zone and the ablation enclosure. [Figure 42] Figure 33 is a cross-sectional view along approximate line 42-42, and more specifically, it shows a pair of air curtains positioned above the opening between the ablation enclosure and the fume extractor. [Figure 43] Figure 33 is a cross-sectional view along line 43-43, which more specifically shows the air pressure sensor coupled to the fume extractor and the inlet port for receiving pressurized air. [Figure 44] Figure 33 is a cross-sectional view along line 44-44, and more specifically, it is a cross-sectional view showing the movement of pressurized air through the internal channel. [Figure 45] Figure 36 is a cross-sectional view along line 45-45, and more specifically, it is a cross-sectional view showing the internal channel branching into a lower conduit and an upper conduit. [Figure 46] Figure 36 is a cross-sectional view along line 46-46, and more specifically, it shows a lower conduit that guides pressurized air to a lower hemispherical slit to generate a lower air curtain across the internal opening of the ablation enclosure, and an upper conduit that guides pressurized air to an upper hemispherical slit to generate an upper air curtain across the internal opening of the ablation enclosure. [Figure 47] This is a cross-sectional view similar to Figure 46, but rotated to further illustrate the flow of pressurized air from the ablation enclosure to the fume extractor, entering through the opening between them and forming the upper and lower air curtains. [Modes for carrying out the invention]

[0051] As illustrated in the illustrative drawings, systems and methods for bonded fasteners are illustrated herein in reference to Figures 1 to 47. As will be further discussed later, the systems and methods disclosed herein can generally be used to automate the preparation and installation of bonded fasteners, including, for example, cleaning the fastener and / or substrate before applying the adhesive, applying the adhesive to at least a portion of either the fastener or the substrate, and then bonding the fastener and substrate along the adhesive line. One or more robotic systems can operate independently and / or simultaneously with each other to prepare the fastener and / or substrate for bonding, to apply the adhesive to the fastener and / or substrate accurately and consistently, and to bond the fastener to the substrate with consistent and reproducible results, and all of these can be integrated into an adaptable modular system that can be deployed in an environment such as an existing manufacturing facility without requiring personal protective equipment ("PPE"), etc.

[0052] The adhesive surfaces of fasteners and substrates can be prepared or treated by a laser ablation process, in which a Class 1M or higher-rated laser, such as an Nd:YAG infrared laser operating at a pulsed wavelength of 1064 nm, operates within a Class 1 certified laser enclosure and rapidly heats the base surface and the contamination layer thereon, burning off oxides and other contaminants from fasteners (e.g., nut plates) and / or substrates (e.g., aircraft flanges). Typically, the base surface of the fastener and / or substrate can be made of metal or similar material and has different thermal properties than the contamination layer from which the laser ablation process is designed to remove. For this reason, the heating and / or cooling rates of the base material (the material being ablated) and the contamination material (if present) vary based on several different factors such as thermal conductivity, mass, thickness, specific heat capacity, laser parameters, and the surrounding environment. The difference in rapid temperature changes caused by the laser weakens the contamination layer and allows it to be removed from the base material without damaging the base material of the fastener or substrate.

[0053] The safety system can monitor laser operation in real time and ensure continuous operation within specific parameters considered safe, without requiring operators to use or wear PPE (e.g., laser safety goggles) or construct a protective laser safety cage. This makes the systems and methods disclosed herein particularly suitable for deployment in environments such as existing manufacturing assembly lines, including manufacturing assembly lines as part of a transportable or mobile workstation. Furthermore, the Dual Check Safety ("DCS") system can be programmed to prevent laser operation unless sensors confirm that the enclosure is properly sealed and operating with Class 1 certified performance. Such sensors include, but are not limited to, an optical sensor that monitors the amount of light (if any) leaking from the enclosure; a proximity sensor that confirms the enclosure is closed; and pressure and / or flow sensors that continuously check the seal and accurately measure the efficiency of debris removal by a vacuum or fume extractor designed to remove ablated debris during operation. Insufficient sealing or a drop in airflow below a threshold level may cause the system to disable the safety interlock and deactivate the laser operation.

[0054] The systems and methods disclosed herein are also designed to reduce variability in the mounting process and increase reliability in a faster and more robust manner than other methods known in the art, including manual mounting. Furthermore, the systems and methods disclosed herein provide appropriately prepared fasteners with the appropriate amount of adhesive to form a repeatable and reliable bond line, thereby increasing efficiency and reducing waste (e.g., discarded adhesive), in addition to improving placement flexibility and safety, as well as reducing manufacturing and assembly costs.

[0055] In one aspect of the embodiments disclosed herein, a laser ablation storage and debris removal system 50 is schematically shown in Figures 1-14 and 6-16. As best shown in Figures 1 and 3, the laser ablation storage and debris removal system 50 is generally composed of three sections: a laser protection chamber 52 substantially aligned with the ablation chamber 54, and a vacuum chamber 56 in fluid communication with the ablation chamber 54. In this regard, the vacuum chamber 56 is designed to continuously remove debris selectively ablated by a laser 58 (Figures 1 and 2) from the substrate in the ablation chamber 54, and the laser 58 is selectively mounted in the laser protection chamber 52 opposite the ablation chamber 54, or otherwise integrated into the laser protection chamber 52. In typical operation, the laser 58 emits a beam which passes through the laser protection chamber 52, through a selectively removable and replaceable protective lens holder 60 (Figure 17), and into the ablation chamber 54 to selectively clean the substrate located in the ablation chamber 5. The protective lens holder 60 has a protective lens (not shown in Figure 17) within it, which is positioned between the laser protection chamber 52 and the ablation chamber 5. The protective lens in the holder 60 is designed to protect the laser 58 from ablated debris from the substrate in the ablation chamber 54, as will be described in more detail later. At this time, as will be described in more detail later, the debris removed from the cleaned substrate is extracted from the ablation chamber 54 by a vacuum chamber 56 which is fluid-coupled with the ablation chamber 54.

[0056] In one embodiment, in order to improve the efficiency and accuracy of laser ablation of the substrate, and thereby achieve a consistent high-quality surface treatment with 6σ reliability during the manufacturing process, while simultaneously reducing surface treatment time and cost, the laser ablation storage and debris removal system 50 may be used in conjunction with a SCARA robot 62 and / or adhesive dispenser 64, for example, part of a transportable roller station 66, as shown in Figures 1 and 2. However, of course, the laser ablation storage and debris removal system 50, the SCARA robot 62, and / or adhesive dispenser 64 may be integrated as part of a stationary or semi-stationary system for use in a manufacturing process that utilizes or integrates the laser ablation storage and debris removal system 50 disclosed herein. In modified embodiments, other robotic arms and / or robotic gantry systems known in the art may be used instead of the SCARA robot 62.

[0057] As shown in Figure 1, the SCARA robot (SCARA) 62 includes an end effector 68 which is selectively engageable with a coupling 70 of the laser ablation storage and debris removal system 50, the coupling 70 which typically extends into the ablation chamber 54 (Figures 3 and 4) through an upper umbrella 72 to couple with a lower-located gripper 74, the gripper 74 which typically includes a pair of working fingers 76 which are sized and shaped to selectively pick up or move substrates requiring cleaning within the ablation chamber 54, such as a nut plate 78 shown in Figure 5. In one embodiment, the gripper 74 may be mechanically or pneumatically driven. However, the gripper 74 may be replaced with another system which can pick up or move laser-irradiated parts, as generally disclosed herein.

[0058] The ablation chamber 54 is generally formed in cooperation with an umbrella portion 72 having a seal ring 80, the seal ring 80 being made of a foam or rubber material circumferentially bonded to the umbrella portion 72 and having dimensions and shape for selective seating acceptance onto the upper rim 82 shown in Figure 4. In this case, when in operation, the SCARA robot 62 operates to position a gripper 74 over one of a number of nut plates 78 requiring ablation (for example, shown in Figure 5), and to actuate the actuating fingers 76 to grip one of the nut plates 78 to remove it from the nut plate carrier 84, and then to transport the selected nut plate 78 over the open upper rim 82 of the laser ablation storage and debris removal system 50. Here, the SCARA robot 62 lowers the gripper 74 holding the selected nut plate 78 into the ablation chamber 54, and the ablation chamber 54 is sealed when the seal ring 80 seats onto the upper rim 82. To ensure a better or substantially airtight seal, the foam or rubber material of the seal ring 80 may be at least partially compressed between the umbrella portion 72 and the upper rim 82. A similar foam or rubber material may be bonded between the end effector 68 of the SCARA robot 62 and the coupling 70 extending upward from the umbrella portion 72 to form an airtight or substantially airtight seal between them. In this regard, the ablation chamber 54 is effectively sealed so that laser light is not emitted from inside the ablation chamber 54 when ablating the nut plate 78 or another substrate.

[0059] This sealing configuration allows the laser ablation containment and debris removal system 50 to function as a Class 1 enclosure, even though a Class 4 laser 58 is being used. Thus, the laser ablation containment and debris removal system 50 can be deployed and operated in a manufacturing environment without requiring the use of laser safety goggles or the installation of a protective laser safety cage. This is particularly beneficial in terms of using the laser ablation containment and debris removal system 50 in conjunction with a transportable roller station 66, because it allows the laser ablation containment and debris removal system 50 to be effectively deployed in an existing manufacturing environment without requiring the manufacturing environment to conform to a certain high-class laser safety standard (for example, without requiring operators to wear laser safety goggles and / or requiring the preparation of an additional laser safety enclosure surrounding the SCARA robot 62). In this case, the ablation chamber 54 is a fully integrated Class 1 laser safety enclosure designed to ensure safety by preventing light from the laser 58 from leaking out of the ablation chamber 54 during operation.

[0060] In another aspect of these embodiments, the umbrella portion 72 may slide along an axis 86 (Figures 3 and 4) perpendicular to the focusing lens of the laser 58 mounted on the opposite side of the laser protection chamber 52. This helps maintain a desired focal distance for the laser 58 of the substrate being ablated in the ablation chamber 54, based on the geometric shape of the substrate being ablated, while also maintaining the proper seal necessary for the laser ablation housing and debris removal system 50 to operate as a Class 1 enclosure.

[0061] In addition, the combination of the umbrella portion 72, the seal ring 80, and the upper rim 82 is versatile in that the geometric shape of each may be changed according to the desired size and / or shape of the part or substrate to be ablated in the laser ablation storage and debris removal system 50. For example, in the embodiments disclosed herein, each of the umbrella portion 72, the seal ring 80, and the upper rim 82 is generally depicted as cylindrical. However, in other embodiments, each of the umbrella portion 72, the seal ring 80, and the upper rim 82 may be made of a different geometric shape (e.g., square, rectangular, triangular) depending on the application. Furthermore, the depth of the ablation chamber 54 formed by the mutual engagement of the umbrella portion 72, the seal ring 80, and the upper rim 82 may also vary according to the size and shape of the part to be ablated. In this regard, for example, relatively large parts require a relatively large depth, while relatively small parts such as the nut plate 78 disclosed herein require a relatively small depth. Furthermore, the size and shape of the gripper 74 and / or its actuating fingers 76, which are operated by the SCARA robot (SCARA) 62, may also be varied according to the desired application (for example, to accommodate parts of different sizes and / or surface areas). Here again, relatively large parts to be cleaned by the laser ablation storage and debris removal system 50 require the use of relatively large grippers and / or actuating fingers, and relatively small parts require the use of relatively small grippers and / or relatively small actuating fingers. In one embodiment, the gripper 74 may have a size and / or shape that can handle materials that may be enlarged or reduced, and may remain controllable by the SCARA robot (SCARA) 62 using input / output ("I / O") command control. In addition, a secondary, relatively large umbrella portion may completely cover the upper rim 82 to accommodate a larger chamber for larger parts beneath the relatively large umbrella portion.

[0062] In another aspect of the embodiments disclosed herein, the components within the ablation chamber 54 are generally positioned at an angle between 90 and 180 degrees relative to the laser 58 and the focal lens of the laser 58. In these embodiments, the laser ablation containment and debris removal system 50 can still operate as a Class 1 enclosure because, as described above, the light from the operating Class 4 laser 58 remains confined within the system 50. This also provides further flexibility, as the laser ablation containment and debris removal system 50 can be deployed in a manufacturing environment without the need for higher-class (e.g., Class 1M or higher) laser operations and the enhanced safety protocols typically associated with them. Furthermore, integration with the SCARA robot (SCARA) 62 and the ability to position components requiring cleaning within the ablation chamber 54 without emitting any substantial amount of laser light from the ablation chamber 54 ensures repeatable and accurate laser operations while maintaining safety.

[0063] Figures 3 and 4 show in more detail a slot 88 formed in the side wall 90 of the laser ablation storage and debris removal system 50, the side wall 90 effectively forming a natural transition between the laser protection chamber 52 and the ablation chamber 54. The slot 88 is sized and shaped to selectively receive and hold a protective lens holder 60 within the slot 88, as generally shown in Figure 2 and in more detail in Figure 17. In one embodiment, the protective lens holder 60 is positioned within the laser protection chamber 52 substantially perpendicular to the direction of light emitted by the laser 58. In this case, the beam of the laser 58 moves through the protective lens in the holder 60 into the ablation chamber 54 to contact the substrate requiring cleaning, for example, the nut plate 78 described above. During ablation, debris ablated from the surface of the substrate enters the ablation chamber 54. Although it is preferable that all debris is immediately discharged from the ablation chamber 54 through the vacuum chamber 56, it is expected that some debris returning towards the laser 58 will remain in the ablation chamber 54. In this regard, the protective lens holder 60 acts as an intermediate to prevent debris remaining in the ablation chamber 54 from contacting or degrading the output lens of the laser 58. Instead, over time, the debris accumulates on the protective lens in the protective lens holder 60 or otherwise damages it. In this case, the protective lens holder 60 can be periodically and selectively removed from the laser protection chamber 52 through the slot 88 in the side wall 94. Once the protective lens holder 60 has been removed, the protective lens inside the protective lens holder 60 may be cleaned and / or selectively replaced, for example, by replacing it with an entirely new protective lens holder 60, or only the protective lens inside the protective lens holder 60 may be replaced, as will be described in more detail later.

[0064] The protective lens holder 60 ensures that the operating laser 58 is substantially protected from damage by debris in the ablation chamber 54, and also allows for the rapid and easy replacement of the protective lens holder 60 after extensive use of the laser ablation storage and debris removal system 50 disclosed herein. In this case, the protective lens holder 60 can protect the relatively expensive laser focusing lens of the laser 58 from debris and other particles in the ablation chamber 54.

[0065] Another feature of the laser ablation storage and debris removal system 50 disclosed herein is a bracket 92 that protrudes inward from the internal side wall 94 within the ablation chamber 54, as best shown in Figure 6 and further shown in Figure 7. The bracket 92 works in cooperation with the internal side wall 94 to form a space or gap 96 between the bracket 92 and the internal side wall 94, which is for selecting a sliding reception of an elastomer fixture 98, for example, any of the nut plates 78 shown in Figure 5. In this case, the SCARA robot (SCARA) 62 may selectively reposition the nut plate 78 inside the ablation chamber 54 to seat the lower portion 100 of the elastomer fixture 98 in the V-shaped intersection 102 (Figure 6) of the bracket 92. At this time, the SCARA robot 62 may selectively reposition the nut plate 78 horizontally, so that the lower portion 100 of the elastomer holder 98 moves within the gap 96 and engages with the V-shaped intersection 102 so that the lower portion 100 is bent out of the path of the laser 58, similar to the position shown in Figure 5 when the adhesive is applied from the tip 104 of the adhesive dispenser 64 to the underside of the nut plate 78. Similarly, by doing so, the bottom of the nut plate 78 is moved into an unobstructed path with the beam of the laser 58, so that the nut plate 78 can be cleaned without interference with the elastomer holder 98. Furthermore, the SCARA robot 62 also operates the gripper 74 to rotate the nut plate 78 approximately 360 degrees, allowing the incident beam from the laser 58 to ablate the entire bottom surface of the nut plate 78. Of course, the lower portion 100 of the elastomer fixture 98 remains substantially bent out of the incident beam and away from the incident beam throughout the entire rotation, due to its engagement with the V-shaped intersection 102 of the inwardly projecting bracket 92, as described above in relation to the position in Figure 5.

[0066] The ablation chamber 54 may also include one or more sensors positioned within the ablation chamber 54 for the purpose of real-time monitoring to ensure that the ablation chamber 54 remains adequately sealed so that there is little to no laser light emission from within the ablation chamber 54. Such sensors may include a pressure sensor to ensure that the ablation chamber 54 is pressurized when the laser 58 is in operation, a proximity sensor to ensure that the seal ring 80 is seated on the upper rim 82, an optical sensor capable of measuring the amount of light leaking from the ablation chamber 54 during use, or another sensor known in the art capable of checking and / or verifying the quality of the seal between the seal ring 80 and the upper rim 82. Each of these one or more sensors integrated with the laser ablation storage and debris removal system 50 may be used alone or in combination with each other to improve safety before, during, and / or after the operation of the laser ablation storage and debris removal system 50.

[0067] In another aspect of these embodiments, Figure 8 is a partial cross-sectional view showing in more detail the internal configurations of the laser protection chamber 52, the ablation chamber 54, and the vacuum chamber 56, respectively, and Figure 9 is an enlarged partial cross-sectional view of circle 9 in Figure 8. In further detail, Figure 8 schematically shows the position of the protective lens holder 60 between the laser protection chamber 52 and the ablation chamber 54 for effectively sealing the laser 58 from the ablation chamber 54. Furthermore, Figure 8 also shows that the ablation chamber 54 is in fluid communication with the vacuum chamber 56 for the purpose of discharging or removing debris from the ablation chamber 54 during the ablation process. In this regard, the vacuum chamber 56 may include a pressure sensor 106 having an open port 108 exposed to the vacuum chamber 56 and capable of monitoring the vacuum pressure within the vacuum chamber 56 in real time. The air pressure sensor 106 provides feedback to the ablation storage and debris removal system 50 to ensure a sufficient seal of the ablation chamber 54 before activating the laser 58; otherwise, the laser ablation storage and debris removal system 50 will not start irradiating with the laser 58. The air pressure sensor 106 also provides real-time feedback during operation, thereby allowing the laser ablation storage and debris removal system 50 to proactively stop the laser 58 if a predetermined pressure loss or low pressure reading occurs in the vacuum chamber 56 during operation. For example, to efficiently remove debris from the ablation chamber 54, sufficient vacuum is further ensured in the vacuum chamber 26 during operation by maintaining sufficient pressure in the laser ablation storage and debris removal system 50.

[0068] Furthermore, the bottom perspective view of Figure 7 shows an inlet port 110 that selectively accepts a pressurized fluid, such as compressed air or pressurized air, used in the ablation chamber 54 (for example, from a pneumatic system) to assist in the formation of the vacuum described above. In this regard, Figure 10 is a partial cross-sectional view showing that the inlet port 110 is fluidly coupled to a separate pressurized air channel 112 formed between the vacuum chamber 56 and the ablation chamber 54. The vacuum pressure sensor 106 is good at ensuring that there is sufficient airflow in the channel 112 to generate a proper vacuum between the inlet port 110 and outlet port 114 (Figure 11) of the vacuum chamber 56, and that such a proper vacuum is sufficient to efficiently draw debris out of the ablation chamber 54 during operation.

[0069] Furthermore, Figure 13 shows a more detailed cross-sectional view of the laser ablation storage and debris removal system 50, where the channel 112 carrying the incoming pressurized air ultimately splits into a lower conduit 116 and an upper conduit 118 at the branching section 120. In this regard, Figure 14 is a cross-sectional view of a modified example, showing that the pressurized air channel 112 is split at the branching section 120, and the incoming pressurized air is immediately diverted into the lower conduit 116 and the upper conduit 118.

[0070] Figure 15 shows that the lower conduit 116 is substantially hemispherical in shape and follows the external geometric shape 122 of the ablation chamber 54. The lower conduit 116 is in fluid communication with a hemispherical slit 124 that opens into the interior 126 of the ablation chamber 54. In this case, pressurized air flows out from the hemispherical slit 124 across the opening of the ablation chamber 54, thereby generating a substantially horizontal air knife or curtain 128, which is designed to substantially reduce the downward movement of slug-like and / or block-like ablated debris into the laser protection chamber 52. Furthermore, the directional arrows in Figure 15 indicate that the pressurized air flowing out from the hemispherical slit 124 as a horizontal air curtain 128 is directed into the vacuum chamber 56. In this case, any debris trapped in this horizontal air curtain 128 is immediately removed from the laser ablation containment and debris removal system 50. Thus, the air curtain 128 constitutes a layer of pressurized air that is constantly flowing, substantially preventing debris from returning to the laser protection chamber 52 where the protective lens holder 60 is located.

[0071] Furthermore, Figure 16 shows that the pressurized air directed into the upper conduit 118 moves into the hollow portion of the bracket 92. Here, Figure 16 shows that the bracket 92 includes a horizontal slit 130 that forms an upwardly projecting air curtain 132. If the surface to be ablated is close to the horizontal slit 130, the debris ablated from the target substrate is immediately pushed upward by the air curtain 132, naturally moving away from the ablated substrate, the horizontal air curtain 128, and the laser protection chamber 52. In this case, this reduces the concentration of debris that may have a tendency to move toward the horizontal air curtain 128 and the ablated substrate. Of course, the horizontal slits 130 and associated curtains 132 may be directed somewhat to push pressurized air toward the vacuum chamber 56, or they may be aligned almost vertically to push the ablated debris upward away from the horizontal air curtain 128, thereby essentially acting as another barrier against the protective lens holder 60. The vertical air curtain 132 also acts to push air toward the vacuum chamber 56, away from the blasted surface of the substrate, preventing debris from accumulating on the newly blasted surface. This further helps to move the debris into the vacuum chamber 56 in order to remove it from the laser ablation storage and debris removal system 50 during operation.

[0072] As a variation, the horizontal air curtain 128 and / or the vertical air curtain 132 may be horizontal and / or vertical and / or at any angle between them, depending on the structure of the laser ablation storage and debris removal system 50 and / or the parts being ablated. For example, the vertical air curtain 132 may be offset by 45 degrees to more efficiently prevent ablated debris from being positioned in the ablation chamber 54 and returning to accumulate along the ablated substrate. Furthermore, either curtain 128, 132 may also be positioned at an offset position relative to either the vertical or horizontal plane to more efficiently direct the pressurized airflow into the vacuum chamber 56. In any of these embodiments, the vacuum chamber 56 may further include, as necessary, one or more HEPA filters and / or one or more carbon filters to collect hazardous or harmful fumes and / or particles at the outlet port 114 or elsewhere.

[0073] Figure 17 further illustrates in detail one embodiment of a protective lens holder 60 having a handle 134, the handle being formed from a pair of arc-shaped recesses 136 facing opposite each other for convenient gripping by hand, thereby allowing the protective lens holder 60 to be easily inserted into and removed from the slot 88. Furthermore, the protective lens holder 60 also includes a substantially circular opening 138, the opening 138 including a receiving channel 140 accessible by a front slot 142, having a size and shape for selectively receiving and holding (e.g., in a friction fit relationship) a protective lens 143, etc. In this regard, the receiving channel 140 effectively holds the protective lens 143 in place within the laser ablation storage and debris removal system 50, thereby allowing the beam emitted by the laser 58 to pass through the protective lens 143 perpendicular to it or otherwise. At the same time, the protective lens 143 is positioned between the laser protection chamber 52 and the ablation chamber 54, effectively preventing the ablated debris from moving back to the laser 58.

[0074] The protective lens holder 60 may be easily accessed by selectively gripping the outwardly extending handle 134 and pulling the arc-shaped recess 136 in order to retract the protective lens holder 60 and disengage it from the slot 88. In one embodiment, the entire assembly of the protective lens holder 60, i.e., the entire assembly including the handle 134, the receiving channel 244, and the protective lens 143 in the receiving channel 244, may be simply discarded or replaced with a new protective lens holder 60 having a clean or undamaged protective lens 143. In a modified embodiment, when the protective lens 143 becomes excessively contaminated (e.g., to remove debris that may accumulate over time) or when it needs to be replaced (e.g., if it is scratched or damaged), once the protective lens holder 60 has been removed, the protective lens 143 may be slid out of the receiving channel 140 through the front slot 142. Subsequently, the cleaned or replaced protective lens 143 is reinserted into the receiving channel 140 by the front slot 142 for further use in the laser ablation storage and debris removal system 50, and then the protective lens holder 60 assembly is reinserted back into the slot 88. Once the protective lens 143 is reinserted into the slot 88, it is effectively sandwiched between the internal side wall and the receiving channel 140 so that it is securely held in the slot 88. Furthermore, the insertion of the protective lens holder 60 into the slot 88 may activate proximity sensors or the like to ensure that the protective lens holder 60 and the protective lens 143 are in proper position before and during operation of the laser 58.

[0075] In this case, the laser ablation storage and debris removal system 50 disclosed herein works in cooperation with a SCARA robot 62 and a Class 4 laser 58 to achieve excellent surface preparation of a nut plate 78, etc., using a Class 1-rated enclosure, which includes an ablation chamber 54 that is in fluid communication with a laser protection chamber 52 (to which the laser 58 is coupled) and a vacuum chamber 56 from which debris and other fumes are exhausted during operation. One or more air curtains 128, 132 reduce slag and prevent blasted debris material from accumulating back on the cleaned substrate and / or protective lens in the holder 60, and help to promote airflow that is easily directed into the vacuum chamber 56. The SCARA robot 62 ensures that the ablation chamber 54 remains properly sealed so that users or people nearby have little to no access to the laser beam during operation. Of course, the ablation chamber 54 may be modified to include the ability to laser different surfaces of different lengths and diameters at different angles, and may be manufactured using various methods, including 3D printing and investment casting.

[0076] Once the nut plate 78 has been ablated using the laser ablation storage and debris removal system 50, the next step is to apply adhesive to the nut plate 78 using an adhesive dispenser 64, as shown in relation to Figures 1-2, 18-19, 21, and 25-26. Briefly as described above, the adhesive dispenser 64 solves the challenge in this technology of precise and repeatable volumetric dispensing of a controlled amount of adhesive on the order of less than about 0.1 grams ("g"), while also controlling the inherent "leakage" or "dripping" of the adhesive at the point of dispensing. In this regard, in one embodiment, the adhesive dispenser 64 may be integrated as part of the laser ablation storage and debris removal system 50, as described in detail above, which is done, for example, by being used in conjunction with a SCARA robot 62 as part of a transport roller station 66 shown in Figures 1 and 2. However, of course, the adhesive dispenser 64 may be integrated as part of a stationary or semi-stationary system for use in a manufacturing process that may utilize or integrate the dispenser 64, as disclosed herein.

[0077] As outlined above, the SCARA robot 62 works in cooperation with a lower-positioned gripper 74 and outwardly extending actuating fingers 76 to automate the process of selectively picking up and moving a substrate to receive the adhesive 144 (Figure 27) onto the substrate, for example, along the bottom surface 146 of a nut plate 78. In one embodiment, the SCARA robot 62 operates the gripper 74 to position one of a number of nut plates 78 on a carrier 84 (for example, shown in Figure 5), operates the fingers 76 to grasp one of the nut plates 78 in order to remove it from the carrier 84, and then transports the selected nut plate 78 within the laser ablation storage and debris removal system 50 for application of the adhesive 144 by the adhesive dispenser 64.

[0078] As best shown in Figure 5, to apply the adhesive 144, SCARA 62 selectively repositions the nut plate 78 so that the lower portion 100 of the elastomer fixture 98, which extends through the nut plate 78, slides within a slot 148 of the locator block 150, which is generally offset from the needle 152 of the adhesive dispenser 64. Then, as shown in Figure 5, SCARA robot 62 selectively repositions the nut plate 78 horizontally so that the elastomer fixture 98 bends around the lower portion 100, i.e., at least the bottom surface 146 of the nut plate 78 aligns with the tip 104 of the needle 152 that dispenses the adhesive 144 without interference from the elastomer fixture 98. Furthermore, SCARA robot 62 also acts on the gripper 74 to rotate the nut plate 78 approximately 360 degrees, thereby consistently distributing the adhesive 144 dispensed from the tip 104 in a circumferential direction. The adhesive dispenser 64 ensures that the bead of applied adhesive 144 is applied substantially consistently to the bottom surface 146, as will be described in more detail later and as shown in Figure 27. Of course, the lower portion 100 of the elastomer fixture 98 remains substantially bent away from the tip portion 104 and rotates within the slot 148 of the locator block 150 during the circumferential application of adhesive 144.

[0079] Figure 18 shows in more detail one embodiment of the adhesive dispenser 64 disclosed herein, in which the tip 104 of a dispensing needle 152 is generally positioned forward and fluidly coupled to an adhesive static mixer 154, which, during operation, selectively receives fluid from a pair of liquid storage cartridges 156, 158. The needle 152 may be held forward by a cradle 160 that is substantially coaxially aligned with each of the tip 104 and the adhesive static mixer 154. The cradle 160 may be coupled to an extension 162 shown in Figure 19, which extends substantially perpendicular to the axial direction of the needle 104 in order to be offset coupled to the front end 164 of a support bracket 166. The support bracket 166 is selectively slidable relative to the housing 168 of the adhesive dispenser 64 by an elongated channel 170 formed along its longitudinal direction. Here, the elongated channel 170 has a size and shape for selecting the passage and acceptance of the shank portions of a pair of bolts 172, which selectively screw into a pair of holes formed in the housing 168. Each of the bolts 172 has a head 174 that is larger than the elongated channel 170, so that when the bolts 172 are screwed into the housing 168, each head 174 cooperates with the housing 168 to clamp the support bracket 166 between the housing 168 and the head 174 in a flat, confinement engagement.

[0080] The position of the front end 164 may be selectively adjusted by loosening each of the bolts 172 at least partially from the housing 168 to release or free the support bracket 166 from the sandwich friction fit between the heads 174 of the bolts 172 and the housing 168. Here, the support bracket 166 remains coupled to the housing 168 by the bolts 172, but is slidable relative to the housing 168 by the shank portion of each bolt 172, the shank portion of each bolt 172 remains within or persists in the elongated channel 170 and at least partially engages with the threaded hole in the housing 168. In this case, the positioning of the support bracket 166 relative to the housing 168 effectively determines the distance at which the cradle-equipped needle 152 (and ultimately the tip portion 104 extending from the needle 152) is positioned relative to the housing 168. Once the desired position of the cradle 160 receiving the needle 152 is set, each of the bolts 172 may be retightened to hold or maintain the support bracket 166 relative to the housing 168.

[0081] The plan view in Figure 19 and the perspective views in Figures 21 to 24 best illustrate that the adhesive dispenser 64 is designed to function with a dual cartridge exchange system 176, which, as will be described in more detail later, generally includes a pair of cartridges 156, 158 (e.g., a standard two-part adhesive cartridge known in the art), the pair of cartridges 156, 158 which are fluidically coupled to a dual cartridge cap 178 (Figure 19), the dual cartridge cap 178 which is fluidically coupled to an adhesive static mixer 154 to deliver the adhesive 144 from the adhesive static mixer 154 to the tip 104 by a needle 152. In one embodiment, for example, the needle 152 is screwed onto one end of the adhesive static mixer 154, and the dual cartridge cap 178 is formed integrally with each of the pair of cartridges 156, 158, as known in the art, and is configured to fluidly snap-fit ​​with the adhesive static mixer 154 at the end opposite to the end into which the needle 152 is screwed. In a modified embodiment, each of the needle 152, the adhesive static mixer 154, the pair of cartridges 156, 158, and / or the dual cartridge cap 178 may be manufactured separately and then assembled in such a manner that the liquid compound in each of the pair of cartridges 156, 158 is dispensed from the pair of cartridges 156, 158 into the dual cartridge cap 178, where it is mixed with each other in the adhesive static mixer 154 and then moved out as adhesive 144 from the tip 104 by the needle 152. In modified embodiments, the dual cartridge exchange system 176 may be a single-piece structure, which may be manufactured by 3D printing or the like.

[0082] As best shown in the perspective views of Figures 21–24, the dual cartridge exchange system 176 selectively slides into a quick-change carrier 180 designed to be slotted into the housing 168 of the adhesive dispenser 64. Figures 22–24 show that the quick-change carrier 180 includes a plurality of outwardly extending bolts 182, each of which has a shank portion 184 smaller in diameter than its respective head portion 184. In this case, each shank portion 184 has a diameter dimensioned to slotted into a pair of receiving channels 188 formed from a pair of receiving rails 190 of the housing 168, but each head portion 186 is too large to fit into the receiving channels 188. The receiving channels 188 may also include a chamfered opening formed from the receiving rails 190 and generally enlarged, so as to provide additional clearance to more easily position each of the shank portions 184 into their respective receiving channels 188 initially. The receiving channel 188 subsequently tapers inward to a width somewhat larger than the diameter of the shank portion 184 for good fixation within the receiving channel 188. The length of the shank portion 184 between the frame 192 and the head portion 184 of the quick change carrier 180 is approximately the same as the width of the receiving rail 190 of the housing 168 to further prevent lateral movement of the quick change carrier 180 when engaged with the housing 168. After the quick change carrier 180 has fully descended into the receiving channel 188, each of the shank portions 184 can engage in front of a pair of lock slots 194, which are oriented approximately 90 degrees forward relative to the receiving channel 188. The quick change carrier 180 remains engaged in front of the lock slots 194 during operation, for example, by a pair of collet assemblies 196, 198, as will be described in more detail later.

[0083] In one embodiment, the quick-change carrier 180 may include a generally open frame structure, as best shown in Figures 21 to 24. In a modified embodiment, the quick-change carrier 180 may be housed in a thermal enclosure 200 (Figures 30 and 31), the thermal enclosure 200 being temperature-controlled by a cooler 202 (Figure 30) and / or one or more heating elements 204 (Figure 31) located therein. Here, the adhesive dispenser 64 can control the temperature of the liquid compound in cartridges 156, 158 of the dual cartridge exchange system 176 based on feedback from one or more temperature sensors located within the enclosure. For example, a single temperature sensor may continuously read the overall temperature within the quick-change carrier 180, or, as a modification, a pair of temperature sensors may individually and continuously read the temperature of each of the cartridges 156, 158. In this latter embodiment, the adhesive dispenser 64 may individually control the temperature of each cartridge 156 and 158 and the temperature of the liquid compound in cartridges 156 and 158 within a certain temperature range or temperature difference range. In this case, the adhesive dispenser 64 can control the temperature of the compound dispensed from cartridges 156 and 158. This feature allows for more precise control of the amount of liquid dispensed from each cartridge 156 and 158, and further controls the viscosity of the adhesive 144 dispensed from the tip 104 of the needle 152.

[0084] Figures 22 and 23 best illustrate the dual cartridge exchange system 176 fully engaged with the quick-change carrier 180. Here, the frame 192 of the quick-change carrier 180 may include a front hole 206, which has a size and shape that allows the adhesive static mixer 154 to pass through and extend. Similarly, as best shown in Figure 24, the frame 192 may also include a relatively large rear hole 208, which has a size and shape that generally accommodates the sliding receptacles of cartridges 156, 158 passing through it. At the same time, the dual cartridge exchange system 176 may also include a base plate 210 that is larger than the rear hole 208 of the frame 192 and extends outward to prevent the dual cartridge exchange system 176 from sliding completely out of the frame 192. In this regard, as best shown in Figure 23 and as described in detail above, the base plate 210 has a surface area that selectively engages with the frame 192 in a coplanar relationship when the collet assemblies 196 and 198 engage with the quick-change carrier 180 at the front in the lock slot 194 of the housing 168.

[0085] Furthermore, when the frame 192 supporting the dual cartridge exchange system 176 is disengaged from its engagement with the housing 168 (for example, as shown in Figure 21), the dual cartridge exchange system 176 may be easily replaced by simply sliding it through the rear hole 208 to disengage it from the frame 192, as generally shown in Figure 24. After removal, a new (fresh / filled) dual cartridge exchange system 176 may be reinserted through (to the extent extending therefrom) each of the rear hole 208 and the front hole 206 until it is positioned as generally shown in Figures 21-23. The quick-change carrier 180 supporting the new dual cartridge exchange system 176 may then be quickly and easily reengaged with the housing 168 by simply sliding the shank portion 184 of the bolt 182 extending outward from the frame 192 into the respective receiving channels 188 and corresponding lock slots 194. Subsequently, the adhesive dispenser 64 may be activated to dispense the adhesive 144 from the tip 104 of the needle 152 in accordance with the embodiments disclosed herein.

[0086] Once the shank portion 184 is fully seated in each of the receiving channels 188, the quick-change carrier 180 may be pushed forward by the drive unit 212 to assist in positioning the shank portion 184 in each of the lock slots 194, in preparation for operating the adhesive dispenser 64. Here, the drive unit 212 acts on a forward-extending screw 214, which screws into a piston slide carrier 216 to which a pair of collet assemblies 196, 198 are rigidly coupled. During operation, the drive unit 212 controls the forward and backward movement of the piston slide carrier 216 by rotating the screw 214 either clockwise or counterclockwise. For example, in one embodiment, by acting on the screw 214 to rotate clockwise, the piston slide carrier 216 is moved forward within the housing 168, pulling each of the collet assemblies 196, 198 to engage with each of the cartridges 156, 158. Conversely, by operating the screw 214 in a counterclockwise direction, the piston slide carrier 118 is moved backward within the housing 168, pulling the collet assemblies 196 and 198 apart from their engagement with cartridges 156 and 158, respectively.

[0087] An upright collet clamp 218, rigidly coupled to the piston slide carrier 216 (best shown in the side views of Figures 18 and 25), selectively clamps each of the collet assemblies 196 and 198 to the piston slide carrier 216. In this case, the movement of the piston slide carrier 216, driven by the drive unit 212, causes the equivalent movement of the collet assemblies 196 and 198, as described above with respect to the screw 214. As shown in the enlarged partial break plan view of Figure 20, each of the collet assemblies 196 and 198 includes an internal piston collet 220 screwed into each of the collet assemblies 196 and 198. Each piston collet 220 terminates in an outward flare mandrel 222 held within a flare sleeve 224, as best shown in Figure 28. The piston collets 220 of collet assemblies 196, 198 are friction-fitted to the piston head 226 by the forward movement of a relatively thin-walled flare sleeve 224 and an outward flare mandrel 222 of the piston collet 220 into a relatively small recess 228 formed within the piston head 226. Here, the relatively thin-walled flare sleeve 224 has the function of being actively attached to the piston head 226. In a modified example, attachment to the piston head 226 may be achieved, for example, by a tapping screw 230 (Figure 29) that is screwed into the piston head 226 by rotating an externally accessible knob 232. In another modified embodiment, the piston head 226 may be modified so that an internal feature "gripping" the piston head 226 from the rear. Each piston head 226 is generally sized and shaped to extend into one of the cartridges 156, 158 in order to push the liquid compound from inside each of the cartridges 156, 158 into the aforementioned dual cartridge cap 178. Each piston head 226 may be the same size or different size depending on the size of the corresponding cartridges 156, 158 and / or the liquid compound to be dispensed from the piston head 226 to make the adhesive 144.

[0088] More specifically, during operation, the drive unit 212 acts on a screw 214 to drive the piston slide carrier 216 forward, thereby extending a pair of collet assemblies 196, 198 rigidly attached to the piston slide carrier 216 into their respective piston collets 220 and the corresponding piston heads 226 coupled thereto into their respective cartridges 156, 158. In response, a predetermined amount of liquid compound from each of the cartridges 156, 158 is pushed into the dual cartridge cap 178, and ultimately into the adhesive static mixer 154, where the compounds from each of the cartridges 156, 158 are sufficiently mixed to form an adhesive 144, which is then dispensed from the dual cartridge exchange system 176 by the tip 104 at the end of the needle 152.

[0089] The drive unit 212 may include one or more sensors that provide real-time feedback on the viscosity of the adhesive 144 being dispensed from the tip 104 of the needle 152. In one embodiment, the sensor is a force feedback sensor that monitors changes in current and / or voltage in the drive motor of the drive unit 212. In response to information from the force feedback sensor, the drive unit 212 adjusts the speed of a screw 214 that operates to push the liquid compound out of the respective cartridges 156, 158. For example, a relatively high current and / or voltage before the adhesive 144 is dispensed from the tip 104 is an indicator that the adhesive 144 has a relatively high viscosity, i.e., has cured beyond the desired level. Here, the drive unit 212 may adjust the speed of the screw 214 that operates to dispense the adhesive 144 by increasing the drive speed into the cartridges 156, 158. Simultaneously, the drive unit 212 may communicate with the SCARA robot 62 to ensure that the nut plate 78 is rotated at a speed sufficient to ensure that the increased speed of the flow of adhesive 144 dispensed from the tip 104 ensures that the adhesive remains evenly applied circumferentially along the bottom surface 146 of the nut plate 78, as shown in Figure 27. Of course, the reverse is also true; that is, if the force feedback sensor determines that the viscosity of the adhesive 144 is lower than desired, the drive unit 212 reduces the speed of the screw 214 that operates to dispense the adhesive 144 by reducing the drive speed to the cartridges 156, 158. Similarly, for example, simultaneously, the drive unit 212 may communicate with the SCARA robot 62 to ensure that the nut plate 78 is rotated at a speed sufficient to ensure that the adhesive 144 dispensed from the tip 104 is still evenly applied circumferentially along the bottom surface 146 of the nut plate 78, as shown in Figure 27, even at the reduced speed. In this case, the force feedback sensor may monitor electronic feedback that takes into account changes in the viscosity of the adhesive 144 in order to control the amount of adhesive 144 dispensed.

[0090] In modified embodiments, the drive unit 212 may include additional or modified sensors that provide modified and / or additional feedback. For example, in one embodiment, a temperature sensor may provide feedback on ambient temperature and adhesive temperature, thereby enabling the drive unit 212 to better calculate the viscosity of the adhesive 144 based on the curing rate in the dual cartridge exchange system 176. For example, in some embodiments, relatively high temperatures may cause mixing of the liquid compounds in the adhesive static mixer 154, resulting in faster curing than at relatively low temperatures, and vice versa. In this case, the drive unit 212 may adjust the speed at which it operates the screw 214 to ensure that the adhesive 144 dispensed from the tip 104 maintains a consistent viscosity. In addition, in other embodiments, other sensors known in the art to help determine the viscosity of the adhesive 144 may be integrated with the drive unit 212. Whether measurements are taken in real time or periodically, the feedback system may fine-tune and adjust the drive motor as needed, thereby dispensing the adhesive 144 with greater accuracy and repeatability.

[0091] In modified embodiments, the adhesive dispenser 64 may include additional “smart” features, such as a timer system and / or a vision system, to provide additional feedback regarding the physical state of the adhesive 144 being dispensed from the tip 104. Such information may be used, as disclosed herein, to further increase the reliability and repeatability of the adhesive dispenser 64, i.e., to apply the adhesive 144 to small parts (e.g., aircraft) in a repeatable and reliable manner.

[0092] After the adhesive 144 has been completely applied circumferentially along the bottom surface 146 of the nut plate 78, the drive unit 212 interrupts the forward movement of the piston slide carrier 216 to stop the flow of adhesive 144 coming out of the tip 104 of the needle 152 while the SCARA robot 62 selects another nut plate that requires adhesive 144 application. However, simply interrupting the forward movement of the screw 214 does not necessarily result in a complete interruption of the adhesive 144 being dispensed from the tip 104, namely, the so-called "leakage" or "dripping" problem arising from residual pressure in dispensing systems known in the art. In this case, to correct this problem, the drive unit 212 not only interrupts the forward movement of the screw 214 but also immediately reverses the screw 214 by a predetermined distance, pulling each of the piston heads 226 backward into the cartridges 156, 158, generating back pressure or vacuum within the cartridges 156, 158, thereby interrupting or stopping the potential forward movement of the adhesive 144 remaining in the adhesive static mixer 154, needle 152, and ultimately the tip 104. The drive unit 212 can achieve such retraction by the rigid engagement of the piston collet 220 with the respective recesses 216 of each piston head 226. In this way, the drive unit 212 can actuate the screw 214 to prevent so-called "leakage" or "dripping". For example, in one embodiment, each piston head 226 may retract into cartridges 156, 158 by tapping screws 230 screwed into the piston head 226, thereby "pulling back" the adhesive 144 and reducing or stopping "leakage" or "dripping" at the tip 104. The amount of retraction may depend on various factors, including the type of adhesive 144 and feedback received by the drive unit 212 from one or more sensors integrated with the automatic adhesive dispenser 64.For example, the drive unit 212 may determine that the screw 214 needs to be retracted a greater distance when the adhesive 144 has a relatively low viscosity when measured in real time by the force feedback sensor, and vice versa.

[0093] When the dual cartridge replacement system 176 requires replacement, the piston collets 220 disengage from each of the piston heads 226, thereby disengaging the collet assemblies 196 and 198 from the cartridges 156 and 158. This disengagement is achieved by using one or both of a pair of flanges 236 (Figures 18 and 19) extending outward from the collet assemblies 196 and 198 to actuate a slide bracket 234 located inside each of the collet assemblies 196 and 198. During normal operation, a step 238 projecting inward from the slide bracket 234 contacts a washer 240 that is spring-biased forward by a spring 242 positioned within a retraction channel 244. By pulling each of the flanges 236 backward toward the drive unit 212, the slide bracket 234 is moved relative to the collet assemblies 196, 198, causing the inwardly projecting step 238 to contact the washer 240 and compress the spring 242 in the pull-in channel 244. In this regard, the intermediately located and inwardly projecting step 246 (Figure 28) may extend between the coils of the spring 242 to assist in the compression of the spring 242. In this case, the slide bracket 234 can move relative to the collet assemblies 196, 198 by a distance predetermined as the length of one or more pull-back channels 248 positioned along the longitudinal direction of the slide bracket 234, and the slide bracket 234 has a slide pin 250 located therein. The backward movement of the slide bracket 234 may also end where the flange 236 is formed by the step or stop 252. This retraction pulls the piston collets 220 out of their respective recesses 228, thereby separating each of the collet assemblies 196 and 198 from the cartridges 156 and 158 of the dual cartridge exchange system 176. In this way, the physical attachment to the piston head 226 within the dual cartridge exchange system 176 may be quickly released from the collet assemblies 196 and 198 by a release mechanism actuated by the slide bracket 234.Once the quick change carrier 180 is released, the dual cartridge exchange system 176 may be cleanly and easily changed by removing the quick change carrier 180 from the housing 168, thereby removing and replacing the dual cartridge exchange system 176 supported by the quick change carrier 180, as described in detail earlier.

[0094] Another feature of the adhesive dispenser 64 is the adhesive purging system, which automatically dispenses small amounts of adhesive 144 to the disposal site when the adhesive's "service life" has expired.

[0095] To this end, the adhesive dispenser 64 can solve the challenge of precise and repeatable volumetric dispensing of adhesive from, for example, a two-part cartridge by using one or more sensors that measure the viscosity of the adhesive in real time to control the amount dispensed onto the bottom surface 146 of a part, for example, a nut plate 78 as shown in Figure 27. Furthermore, the adhesive dispenser 64 also includes a “pullback” collet feature, which allows the dispenser 64 to retract the piston head 226 in cartridges 156, 158 to control the inherent “leakage” and / or “dripping” of the adhesive 144 at the location of the dispensed material caused by residual pressure in the dispensing system.

[0096] In another aspect of the systems and methods disclosed herein, the substrate ablation and debris removal system 254 (shown in Figures 32 to 47) may be integrated as a separate step or station associated with a laser ablation housing and debris removal system 50 and / or adhesive dispenser 64 to provide a more flexible, efficient, and consistent process for cleaning parts and fixing them to the substrate with adhesive. More specifically, as shown in Figure 32, a collaborative robot ("cobot") 256 is coupled to the substrate ablation and debris removal system 254 by a mount 258, which selectively engages with a housing 260 housing an infrared laser 262 (e.g., a Class 4-rated laser), as best shown in Figure 32. The infrared laser 262 generates a laser beam, which transmits infrared light through the mount 258 and the laser protection zone 264 into a Class 1-rated ablation enclosure 266 to ablate components or substrates within the ablation enclosure 266. In embodiments disclosed herein, the infrared laser 262 is used to ablate a substrate such as a bracket 268 (shown, for example, in Figures 36-38), thereby preparing the bracket 268 for mounting a nut plate 78, etc., on it by adhesive 144. Of course, the infrared laser 262 may also be used to ablate other substrates, which, according to embodiments disclosed herein, are, for example, airplane wings (or other surfaces of an airplane or vehicle). Thus, the mount 258 is designed to fix the infrared laser 262 in a position that cooperates with the laser protection zone 264 and the ablation enclosure 266, and prepares the bracket 268 to receive the nut plate 78 in an adhesive manner by removing debris (e.g., primer, etc.) from the bracket 268 without damaging the material composition of the ablated bracket 268.For this purpose, the mount 258, housing 260, laser protection zone 264, and ablation enclosure 266 work together to operate the Class 4 infrared laser 262 within a Class 1 rated enclosure. Thus, the infrared laser 262 can be operated in a safer manner without the operator needing to wear safety goggles and / or without the need to prepare an additional laser safety enclosure.

[0097] Figures 33–35 show the mount 258 in more detail, which is mounted on the upper or upper portion of the laser protection zone 264, which generally has a conical or frustoconical shape. The laser protection zone 264 and the ablation enclosure 266 are generally configured separately by a separate protective lens holder 60' (Figure 17) that is selectively removable and replaceable, and the protective lens holder 60' is positioned between the laser protection zone 264 and the ablation enclosure 266, for example, as best shown in Figures 33 and 34. The protective lens holder 60' completely or substantially seals the laser protection zone 264 from the ablation enclosure 266, so that the laser lens within the housing 260 is not affected by dispersed debris and / or other particulate matter blown off from the bracket 268 of target during ablation.

[0098] Furthermore, the substrate ablation and debris removal system 254 may further include a fume extractor 270 in fluid communication with the ablation enclosure 266, as best shown in the cross-sectional views of Figures 39 and 42. In this regard, the fume extractor 270 is designed to continuously remove debris selectively ablated from the bracket 268 within the ablation enclosure 266 by an infrared laser 262 (Figure 32). In typical operation, the infrared laser 262 emits a beam, which travels into the ablation enclosure 266 through a laser protection zone 264 and a selectively removable and replaceable protective lens holder 60' positioned between the laser protection zone 264 and the ablation enclosure 266, in order to selectively clean the bracket 268 enclosed within the ablation enclosure 266. Next, as will be explained in more detail later, the debris ablated from the bracket 268 within the ablation enclosure 266 is removed from the ablation enclosure 266 by the vacuum generated in the substrate ablation and debris discharge system 254, thereby fluidly extracting or removing the debris from within the ablation enclosure 266.

[0099] Similar to the laser ablation storage and debris removal system 50 and the adhesive dispenser 64, the substrate ablation and debris removal system 254 may be used as part of a transportable roller station 66', as shown, for example, in Figure 32. However, of course, the substrate ablation and debris removal system 254, the cobot 256, and its associated components, such as the mount 258, housing 260, infrared laser 262, laser protection zone 264, ablation enclosure 266, and / or fume extractor 270, may be integrated as part of a stationary or semi-stationary system for use in a manufacturing process that may utilize or integrate the substrate ablation and debris removal system 254 more permanently, as disclosed herein. In additional modified embodiments, any robotic arm known in the art may be used instead of the cobot 256.

[0100] As best shown in Figures 33-35, the ablation enclosure 266 includes a relatively rigid base 272, the base 272 having a lower sealing member 274 coupled to its upper surface 276 (best shown in Figure 44), the lower sealing member cooperating with an upper sealing member 278 extending outward from one end of a laser protection zone 264 generally facing the mount 258. In one embodiment, the base 272 and the lower sealing member 274 coupled thereto are selectively movable relative to the upper sealing member 278 by coupling with a linear actuator or pneumatic piston 280, where the piston 280 may move the base 272 between an open position (Figures 33-34 and 36-37) and a closed position (Figure 38). To provide further stability during movement between the open and closed positions, the base 272 may include a pair of upwardly extending guide posts 282, which selectively slide within a pair of slide channels 284 (Figures 45 and 47) formed from a pair of legs 286 extending outward from the outer surface 288 (Figure 36) of the laser protection zone 264. The pair of guide posts 282 effectively prevent the base 272 from rotating relative to the laser protection zone 264 during pneumatic movement.

[0101] The lower sealing member 274 includes an upright circumferential side wall 290 that terminates at an upper rim 292 which forms an internal cavity 294. The upper rim 292 is substantially flat and designed to engage flush with the bottom surface 296 of the carrier 298 (Figures 36-38), and the carrier 298 has one or more brackets 268 coupled to it. Similarly, the upper sealing member 278 also includes a downwardly projecting circumferential side wall 300, which terminates at a lower rim 302 which forms an internal cavity 304 (Figure 35) within the side wall 300. The lower rim 302 is substantially flat and designed to engage flush with the top surface 306 of the carrier 298, and the carrier 298 has one or more brackets 268 coupled to it. Furthermore, each of the internal cavities 294, 304 is generally relatively wide and / or deep enough to completely enclose and surround the bracket 268 or other component when seated on the bottom surface 296 and top surface 306 of the carrier 298, respectively. Each of the lower sealing member 274 and / or upper sealing member 278 may be made of at least some compressible foam or rubber material so that when the lower sealing member 274 and / or upper sealing member 278 are seated on the surfaces 296, 306, respectively, the bracket 268 or other component is vacuum-sealed within the internal cavities 294, 304. However, in other embodiments, the lower sealing member 274 and / or upper sealing member 278 may be made of other materials, as long as the lower sealing member 274 and upper sealing member 278 can form the vacuum seal disclosed herein. By compressing the sealing members 274 and 278 toward the surfaces 296 and 306, it is ensured that laser light is not emitted from the ablation enclosure 266 when the infrared laser 262 is activated.

[0102] Accordingly, in one embodiment, the respective depths of the internal cavities 294, 304 may be selected to prepare for compatibility with main components of different sizes, such as the brackets 268 shown in Figures 36-38. In the embodiments shown in Figures 36-38, the upper rim 292 of the lower sealing member 274 seats on the bottom surface 296 of the carrier 298 to form a circumferential seal below the bracket 268, and the lower rim 302 of the upper sealing member 278 seats on the top surface 306 of the carrier 298 to form a circumferential seal above the bracket 268 (including above the base material 308 and above the upwardly extending flange 310). Here, the sealing members 274, 278 sandwich the carrier 298 between them, effectively sealing the bracket 268 of the carrier 298. This seal helps prevent light from the infrared laser 262 from leaking out of the ablation enclosure 266 and generates a vacuum inside the ablation enclosure 266. Of course, in modified embodiments, each of the sealing members 274 and 278 may be of a different size, may be removable, and may be interchangeable, for example, if the sealing members 274 and 278 wear out over time or if there is a need for interchangeability of parts requiring sealing members 274 and 278 of different sizes.

[0103] During operation as shown in Figures 36-38, the cobot 256 first operates to position the ablation enclosure 266, for example, as shown in Figure 36, positioning the upper sealing member 278 on one of the brackets 268 of the carrier 298 that requires ablation. The cobot 256 then lowers the assembly so that the lower rim 302 of the upper sealing member 278 seats on the upper surface 306 of the carrier 298, thereby enclosing the bracket 268 (including the base material 308 and the upwardly extending flange 310) within the upper sealing member 278. As shown in Figure 37, the upper sealing member 278 generally forms an airtight seal with the upper surface 306. In some embodiments, this seal may be sufficient to form a Class 1 enclosure when ablating a surface that is too large to clamp, such as an airplane wing or other surface. In another embodiment, the cobot 256 may actuate the piston 280 to pull up the upper rim 292 of the lower sealing member 274, as shown in Figure 38, to engage with the bottom surface 296 of the carrier 298. The lower sealing member 274 and the upper sealing member 278 function with each other when in this position to form an airtight or substantially airtight seal with the carrier 298 sandwiched between them. Here, the ablation enclosure 266 is effectively sealed to prevent or substantially prevent light emitted by the infrared laser 262 from leaking out of the ablation enclosure 266. In this case, the Class 4 infrared laser 262 operates within a Class 1-rated enclosure of the substrate ablation and debris removal system 254. Here, the infrared laser 262 is considered safe to operate in a manufacturing environment without requiring additional safety measures such as safety goggles or a laser safety cage, as described above.This is particularly beneficial in that the substrate ablation and debris removal system 254 is used in conjunction with a transportable roller station 66', because it can be effectively deployed anywhere, including existing manufacturing environments, without the need to conform the manufacturing environment to certain high-class laser safety standards (e.g., requiring operators to wear laser safety goggles or constructing a laser safety cage surrounding the cobot 256 and its assemblies). In this case, the ablation enclosure 266 is a fully integrated Class 1 laser safety enclosure designed to ensure safety by preventing light from the infrared laser 262 from leaking out of the ablation enclosure 266 during operation.

[0104] The lower sealing member 274 and the upper sealing member 278 are versatile in that their respective geometric shapes may be modified according to the desired size and / or shape of the bracket, component, or substrate to be ablated by the substrate ablation and debris removal system 254. For example, in some embodiments disclosed herein, each of the lower sealing member 274 and the upper sealing member 278 is generally shown as cylindrical, and the upper sealing member 278 is mounted on a laser protection zone 264 which generally has a conical shape. In other embodiments, each of the lower sealing member 274 and the upper sealing member 278 may be made of a different geometric shape (e.g., square, rectangular, triangular) depending on the application. Furthermore, the depth of the ablation enclosure 266 formed by the typical hollow internal cavities 294, 304 of the lower sealing member 274 and the upper sealing member 278, or by the hollow internal cavity 294 of the upper sealing member 278 in embodiments where the lower sealing member 274 is not required, may also vary depending on the size and shape of the part or surface to be ablated. In this regard, for example, relatively large parts require a relatively large depth, while relatively small parts such as the bracket 268 disclosed herein require a relatively small depth. In addition, the size (height) of the opening between the lower sealing member 274 and the upper sealing member 278 may also vary, for example, based on the length of the piston 280 and the support guide post 282 to accommodate relatively large or relatively small parts.

[0105] In another aspect of the embodiments disclosed herein, one or more surfaces to be cleaned within the ablation enclosure 266 may generally be oriented at an angle between 90 and 180 degrees with respect to the focusing lens of the infrared laser 262. For example, in the embodiments shown in Figures 36–38, the substrate 308 is angled at approximately 90 degrees with respect to the focusing lens of the infrared laser 262 by positioning the plane of its surface substantially perpendicular to the ablation beam. In a variation, the laser protection zone 264 may be internally adapted to allow the emitted beam to more effectively ablate one or more surfaces to be cleaned. For example, in one embodiment, to prepare a surface that is not perpendicular or perpendicular to the focusing lens of the infrared laser 262, the housing 260 may be coupled to the mount 258 at an angle that offsets the beam angle in a way that the infrared laser 262 is not concentric or centered within the laser protection zone 264. Here, even in embodiments where the laser beam is concentric within the laser protection zone 264, one or more adaptable fixtures, such as mirrors 311 (Figure 39), may be added within the laser protection zone 264 to change the orientation of the beam path and ablate surfaces offset 180 degrees upward with respect to the focal lens of the infrared laser 262. Furthermore, one or more prisms 313 may be placed inside the laser protection zone 264 to split a single beam into multiple beams to ablate multiple surfaces simultaneously. In this embodiment, these internally placed mirrors 311 and / or prisms 313 enable simultaneous ablation of a substrate 308 substantially perpendicular to the beam path and a flange 310 offset approximately 180 degrees from the beam path and extending upward. Of course, the prisms 313 may be used alone or in combination with one or more mirrors 311 as described above, depending on the application. The mirror 311 and / or prism 313 may be mounted on a pivot 315 (e.g., a single-plane or multi-plane pivot similar to a ball-socket joint) and be repositionable in real time within the laser protection zone 264 during the ablation process.Modifying the laser protection zone 264 to include the mirror 311 and / or prism 313 helps to prepare and clean surfaces that are difficult to enter and reach within the linear beam path.

[0106] In addition, the laser protection zone 264 may be further modified to include an external mount or bracket, such as bracket 268, which helps maintain the infrared laser 262 in a perpendicular alignment with respect to the workpiece. Furthermore, the length and diameter of the laser protection zone 264 may be varied to accommodate the required laser irradiation area and different focal lengths. These modifications and other modifications disclosed herein enhance the versatility and functionality of the laser protection zone 264, thereby making it more efficient and effective for a wide range of applications.

[0107] As shown in Figure 35 and the cross-sectional view in Figure 39, the laser protection zone 264 includes a slot 312 formed in its side wall, which is for the selective acceptance and retention of the protective lens holder 60'. This forms a natural transition between where the laser protection zone 264 ends and where the ablation enclosure 266 begins. The beam of the infrared laser 262 travels through the protective lens holder 60' into the ablation enclosure 266 to contact parts requiring cleaning, such as the aforementioned bracket 268. During ablation, debris ablated from the surface of the bracket 268 (e.g., the substrate 308 or the upwardly extending flange 310) enters the ablation enclosure 266. It is preferable that all debris be immediately discharged from the ablation enclosure 266 through the fume extractor 270, but it is expected that some debris will remain in the ablation enclosure 266 and tend to return towards the infrared laser 262. In this regard, the protective lens holder 60' functions as an intermediate, similar to the lens 60 described above, and the intermediate prevents debris remaining in the ablation enclosure 266 from being emitted and coming into contact with or otherwise degrading the output lens of the infrared laser 262. Over time, the debris accumulates on the protective lens 143 in the protective lens holder 60' rather than the relatively expensive laser lens, or otherwise damages it. If the protective lens holder 60' is selectively removable and replaceable within the slot 312, the protective lens 143 can be periodically changed for cleaning and replacement, even if it is damaged or contains excessive debris.

[0108] In one embodiment, the protective lens holder 60' may have the same or similar structure as the protective lens holder 60 described above and illustrated in conjunction with Figure 17, for the purpose of protecting the laser 58. For example, the protective lens holder 60' may also include a handle 134, which is formed from a pair of arc-shaped recesses 136 facing opposite directions for convenient gripping by hand, thereby making it easier to insert and remove the protective lens holder 60' from the slot 312. Furthermore, the protective lens holder 60' may also include a substantially circular opening 138 having a receiving channel 140 accessible by a front slot 142, the receiving channel 140 having a size and shape for selectively receiving and holding (e.g., in a friction fit relationship) a protective lens 143, etc. In this regard, as described above, the receiving channel 140 holds the protective lens 143 in place within the substrate ablation and debris discharge system 254, allowing the beam emitted by the infrared laser 262 to pass through the protective lens 143 either perpendicular to it or otherwise. At the same time, the protective lens 143 is positioned between the laser protection zone 264 and the ablation enclosure 266, effectively preventing the ablated debris from returning to the infrared laser 262.

[0109] The protective lens 143 can be easily accessed by selectively gripping the outwardly extending handle 134 and pulling the arc-shaped recess 136 to retract the protective lens holder 60' and disengage it from the slot 312. In one embodiment, the entire assembly of the protective lens holder 60', i.e., the entire assembly including the handle 134, the receiving channel 140, and the protective lens 143 therein, may be simply discarded or replaced with a new protective lens holder 60', the new protective lens holder 60' having a clean, i.e., undamaged protective lens 143 therein. In a modified embodiment, once the protective lens 143 has been removed, it may be slid out of the receiving channel 140 by the front slot 142 for cleaning (e.g., to remove debris that may accumulate over time) or for replacement (e.g., if scratched or damaged). Subsequently, the cleaned or replaced protective lens 143 may be reinserted into the receiving channel 140 through the front slot 142, and then the protective lens holder 60' assembly may be reinserted into the slot 312 for further use in the substrate ablation and debris removal system 254. Once the protective lens 143 has been reinserted into the slot 312, it may be effectively sandwiched between the inner side wall and the receiving channel 140 to ensure secure retention. Furthermore, to ensure that the protective lens holder 60' is in place before and during the operation of the infrared laser 262, the insertion of the protective lens holder 60' into the slot 312 may activate proximity sensors or the like.

[0110] During operation, when the ablation enclosure 266 is in a sealed relationship with the carrier 298, the substrate ablation and debris removal system 254 can pressurize the enclosure 266 and the corresponding fume extractor 270 (Figure 42), which is fluidly coupled to it, to create a vacuum within them, thereby drawing the debris through the fume extractor 270 during operation. Here, the air pressure sensor 314 may include an open port 316 (Figures 40 and 43-44) fluidly coupled to the fume extractor 270 to measure the pressure inside the ablation enclosure 266 and the fume extractor 270 in real time to ensure that one or both of the lower sealing member 274 and the upper sealing member 278 form an airtight seal with, for example, the carrier 298. The presence of this pressure difference ensures the closure and seal of the ablation enclosure 266, ensures the continuous operation of the Class 4 infrared laser 262 within the Class 1 enclosure, and ensures that the ablated debris from the workpiece is efficiently removed from the operating ablation enclosure 266. Such pressurization may be achieved by using a pneumatic system utilizing compressed air.

[0111] In another aspect of the embodiments disclosed herein, the substrate ablation and debris removal system 254 may further include a gripper 318, which typically includes a pair of fingers 320, the pair of fingers 320 being actuated, for example, by an air solenoid 322 or a similar pneumatic or electric actuator, to facilitate handling of a scalable material, such as the elastomer fixture 98 shown in Figures 5-7. Here, the fingers 320 are pneumatically actuated by the air solenoid 322 to compress the elastomer fixture 98 in a manner that grips one end thereof. Thus, the cobot 256 pulls the elastomer fixture 98 downward, thereby pulling the nut plate 78 attached to the elastomer fixture 98 and having adhesive 144 on its underside, and engaging it with the substrate 308. In these embodiments, the gripper 318 and / or the pneumatic sealing system described above may be integrated with and controlled by a robotic system that utilizes input / output ("I / O") commands.

[0112] The gripper 318 and / or its operating fingers 320, operated by the cobot 256, may be modified in size and shape depending on the desired application (for example, to accommodate parts of different sizes / shapes). In this case as well, relatively large parts to be cleaned by the substrate ablation and debris removal system 254 may require the use of a relatively large gripper and / or relatively large operating fingers, and relatively small parts may require the use of a relatively small gripper and / or relatively small operating fingers. In one embodiment, the gripper 318 may be sized and / or shaped to handle scalable materials, such as the elastomer fixture 98 described above, and may remain controllable by the cobot 256 using input / output ("I / O") command control.

[0113] In another aspect of these embodiments, Figures 39 and 41-42 are cross-sectional views showing in more detail the internal configurations of the laser protection zone 264, the ablation enclosure 266, and the fume extractor 270, respectively. More specifically, Figures 39 and 42 generally show the position of a protective lens holder 60' between the laser protection zone 264 and the ablation enclosure 266 for effectively sealing the infrared laser 262 therefrom. Furthermore, Figures 39 and 42 also show that the ablation enclosure 266 is in fluid communication with the fume extractor 270, for example, through an opening 324 between them, for the purpose of discharging or extracting debris from the ablation enclosure 266 during the ablation process. As briefly mentioned earlier and as shown in Figure 40, the fume extractor 270 may include an air pressure sensor 314, the open port 316 of which is exposed to the vacuum pressure inside the fume extractor 270, allowing the vacuum pressure inside the fume extractor 270 to be monitored in real time. The air pressure sensor 314 may provide feedback to the substrate ablation and debris removal system 254 to ensure a complete seal of the ablation enclosure 266 before activating the infrared laser 262. The air pressure sensor 314 may also help ensure that the vacuum in the operating fume extractor 270 is adequate to ensure efficient removal of debris from the ablation enclosure 266, for example, while the substrate ablation and debris removal system 254 is in use.

[0114] As a variation or additional example, the ablation enclosure 266 may also include one or more sensors placed inside the ablation enclosure 266 for real-time monitoring, for example, to ensure that the ablation enclosure 266 remains properly sealed and that light from the infrared laser 262 does not leak during operation. This helps ensure that the substrate ablation and debris removal system 254 continues to operate as a Class 1 enclosure despite utilizing a Class 4 laser. Such sensors may include a pressure sensor equivalent to the air pressure sensor 314 to further ensure that the ablation enclosure 266 remains pressurized when the infrared laser 262 is in operation. In another embodiment, the ablation enclosure 266 may include one or more proximity sensors to help ensure that the lower sealing member 274 properly seats on the bottom surface 296 of the carrier 298 and / or that the upper sealing member 278 properly seats on the top surface 306 of the carrier 298. In another embodiment, the ablation enclosure 266 may include a photosensor capable of measuring the relative amount of light leaking from the ablation enclosure 266 during use. In this embodiment, a light curtain may be used to shield the sensor from inaccurate readings due to ambient light in the production environment. In addition, other sensors known in the art may be used, provided that such sensors can check and / or verify the performance of the seal between the sealing members 274, 278 and the carrier 298, and provide real-time feedback so that the substrate ablation and debris removal system 254 can turn off the infrared laser 262 if the enclosure no longer conforms to Class 1. Each of one or more sensors integrated with the substrate ablation and debris removal system 254 may be used alone or in combination with each other to improve safety before, during, and / or after the operation of the substrate ablation and debris removal system 254.

[0115] As best illustrated in Figures 42-44, the inlet port 326, typically formed between the laser protection zone 264 and the fume extractor 270, selectively accepts a pressurized fluid, such as compressed or pressurized air from a pneumatic system. More specifically, Figures 42 and 44 show that the inlet port 326 is fluidically coupled with a channel 328, which carries the pressurized air entering between the fume extractor 270 and the ablation enclosure 266 downwards. The pressurized air is used to create the aforementioned vacuum for expelling debris from the fume extractor 270. In this case, the aforementioned air pressure sensor 314 within the fume extractor 270 may ensure that there is sufficient airflow in the channel 328 to create a proper vacuum between the inlet port 326 and outlet port 330 (Figures 33-35 and 40-42) of the fume extractor 270 in order to draw debris out of the ablation enclosure 266 during operation.

[0116] Figures 45 and 46 show that the pressurized air channel 328 ultimately divides into a lower conduit 332 and an upper conduit 334 at its branching point 336. From here, Figures 45–47 best illustrate that the lower conduit 332 is generally hemispherical and follows the curved inner surface 338 of the ablation enclosure 266. The lower conduit 332 is in fluid communication with a lower hemispherical slit 340, which opens into an internal opening 342 of the ablation enclosure 266. In this case, the pressurized air flows out through the lower hemispherical slit 340 and across the internal opening 342 to generate a lower air knife or air curtain 344 (indicated here by a pair of directional arrows), which is designed to substantially reduce the slag and / or prevent the ablated debris from moving into the laser protection zone 264. The lower hemispherical slit 340 is located somewhat above the internal opening 324 between the ablation enclosure 266 and the fume extractor 270, thereby providing some downward pressure into the opening 324 for the final extraction out of the fume extractor 270 by pressurized air flowing out of the lower hemispherical slit 340 as a lower air curtain 344. In this case, the lower air curtain 344 constitutes the first shield for changing or reversing the orientation of the ablated and upward-radiated debris toward the protective lens holder 60' and the laser protection zone 264 by forming a first layer of pressurized air that is always flowing across the internal opening 342.

[0117] Furthermore, Figures 45–47 also show that the upper conduit 334 is generally hemispherical and follows the curved inner surface 338 of the ablation enclosure 266, which is equal to the lower conduit 332. Here, the upper conduit 334 is in fluid communication with an upper hemispherical slit 346 that opens into an internal opening 342 of the ablation enclosure 266. In this case, pressurized air flows out of the upper hemispherical slit 346 across the internal opening 342 of the ablation enclosure 266, generating a second upper air knife or air curtain 348, which is designed to reduce any escape or other movement of residual slag and / or ablated debris around the lower air curtain 344. The pressurized air released from the upper hemispherical slit 346, positioned above the lower hemispherical slit 340, provides an additional downward pressure acting in the opposite direction to any ablated and upward-moving debris. In this case, the upper hemispherical slit 346 and the upper air curtain 348 constitute a second shield, which is designed to keep debris and other particles away from the laser protection zone 264 and move them into the fume extractor 270 through the opening 324, which is in fluid communication with the ablation enclosure 266.

[0118] When each of the sealing members 274 and 278 is seated on the respective surfaces 296 and 306 of the carrier 298, the fume extractor 270 is completely sealed by the ablation enclosure 266, facilitating efficient removal of contaminants by a sealed airtight vacuum seal that prevents the user from being exposed to harmful airborne particles. In this case, the vacuum generated within the fume extractor 270 draws out laser-irradiated fumes and other particles within the ablation enclosure 266. In one embodiment, the fume extractor 270 may have one or more HEPA filters and / or one or more carbon filters to collect these hazardous or harmful fumes and / or particles at an outlet port 330 or elsewhere when needed. The air pressure sensor 314 reads the pressure in real time from inside the fume extractor 270 and provides feedback to the substrate ablation and debris removal system 254 regarding the quality of the vacuum inside the fume extractor 270 to ensure that the ablation enclosure 266 remains sealed for safety purposes. If the pressure drops below a predetermined threshold, the substrate ablation and debris removal system 254 may cut off the infrared laser 262 in real time to stop the ablation process.

[0119] The laser protection zone 264, the ablation enclosure 266, and / or the fume extractor 270 may be manufactured by a variety of processes, such as 3D printing using FDM, 3D printing using SLA resin, 3D printing using SLS, investment casting using a wax core for internal passages (e.g., channel 328), or machining. The shape of the substrate ablation and debris removal system 254 is not necessarily limited to a conical shape and may be designed as a box shape or any other shape as needed.

[0120] In addition, the substrate ablation and debris removal system 254 may also be used in conjunction with modified methods for surface treatment / activation, such as dry ice, plasma, or media blasting. These modified processes provide additional flexibility in selecting the most suitable method for ablating the surface depending on the specific manufacturing, assembly, or repair needs.

[0121] In this case, the substrate ablation and debris removal system 254 is generally configured to use a Class 4 infrared laser 262 within a Class 1 laser safety enclosure, the Class 1 laser safety enclosure includes a laser protection zone 264 generally aligned to emit the beam through a protective lens holder 60' into the ablation enclosure 266, the ablation enclosure 266 is fluidly coupled to a fume extractor 270, and during operation, debris and other fumes are discharged from the substrate ablation and debris removal system 254 in the fume extractor 270. One or more air curtains 344, 348 help reduce slag, help prevent blasted debris material from accumulating back onto the cleaned substrate and / or protective lens 143 within the protective lens holder 60', and help facilitate a directional airflow to the fume extractor 270. The cobot 256 ensures that the two-part ablation enclosure 266 remains properly sealed, thereby ensuring that little to no laser light is emitted from the ablation enclosure 266 during operation. Of course, the ablation enclosure 266 may be modified to include the ability to irradiate different surfaces with the laser at different angles, different lengths, and different diameters, and may be manufactured using various methods, including 3D printing and investment casting, as described above.

[0122] Although several embodiments have been described in detail for illustrative purposes, various modifications may be made without departing from the scope and spirit of the invention. Accordingly, the invention is not limited to those defined by the appended claims.

Claims

1. A laser ablation storage system, A laser chamber integrated with a Class 1M or higher-rated laser, A cleaning chamber coupled to and aligned with the laser chamber is included for selectively receiving the beam generated by the laser, which is classified as Class 1M or higher. A laser ablation storage system comprising a cleaning chamber including a header, the header being selectively movable between a first position that exposes the interior of the cleaning chamber for placing a substrate inside the cleaning chamber and a second position that securely closes the interior of the cleaning chamber, the header cooperating with the laser chamber in the second position to form an enclosure capable of operating a Class 1 certified laser.

2. The laser ablation storage system according to claim 1, wherein the laser chamber and the cleaning chamber are integrated as part of a transportable roller station.

3. The laser ablation storage system according to claim 1, wherein the cleaning chamber and the laser chamber are coupled to a robotic arm, and the robotic arm is movable to selectively position the header so as to face the substrate in order to form an enclosure including the cleaning chamber and the laser chamber.

4. The laser ablation storage system according to claim 1, wherein the cleaning chamber is in fluid communication with the debris removal chamber.

5. The laser ablation storage system according to claim 1, further comprising a gripper having a pair of working fingers, the gripper being positioned below the umbrella portion and operable to perform selective pick-and-place of the substrate within the enclosure formed by a sealing engagement between the umbrella portion and a seal rim.

6. The laser ablation storage system according to claim 5, wherein the umbrella portion is slidable along an axis perpendicular to the focusing lens of a laser that is classified as Class 1M or higher and is mounted in the laser chamber.

7. Furthermore, the laser ablation storage system according to claim 5, further comprising a proximity sensor, the proximity sensor being positioned to identify when the umbrella portion is seated on the seal rim.

8. The laser ablation housing system according to claim 1, wherein the header includes a compressible liner projecting outward, the liner forming at least a portion of the outer periphery of the enclosure.

9. Furthermore, the laser ablation storage system according to claim 1 further includes at least one sensor for measuring pressure or light within the enclosure.

10. The laser ablation storage system according to claim 1, further comprising a protective lens, the protective lens being selectively positionable within a slot so as to be removable and replaceable, and the protective lens substantially sealing the laser chamber from the cleaning chamber.

11. The laser ablation storage system according to claim 10, wherein the protective lens is held by a lens holder, thereby locking the protective lens within the lens holder, and the lens holder has a forward channel that provides access to the protective lens when removing the protective lens from the slot, and the forward channel is coplanar with the inner side wall of the cleaning chamber when the protective lens is in the slot.

12. The laser ablation storage system according to claim 1, wherein the header includes a clamp having a base, the base having a lower sealing member extending upward from the base, and the lower sealing member cooperates with an upper sealing member when the header is in the second position to form the enclosure between the lower sealing member and the upper sealing member.

13. The laser ablation storage system according to claim 12, wherein the lower sealing member comprises a foamed material or a rubber material and is movable relative to the upper sealing member comprising the foamed material or a rubber material by a linear actuator or a pneumatic piston.

14. The laser ablation storage system according to claim 1, wherein the laser chamber is offset from the cleaning chamber by an angle of 90 to 180 degrees.

15. The laser ablation storage system according to claim 1, further comprising a mirror or prism located within either the laser chamber or the cleaning chamber, wherein the mirror or prism is positioned to receive the beam and redirect it again after offsetting it by an angle of up to 180 degrees.

16. The laser ablation storage system according to claim 15, wherein the mirror or prism is mounted on a pivot and can be repositioned in real time within either the laser chamber or the cleaning chamber.

17. The laser ablation storage system according to claim 16, wherein the pivot includes a single-planar pivot, a multi-planar pivot, or a ball-socket type pivot.

18. The laser ablation storage system according to claim 1, further comprising a bracket protruding inward from the inner side wall of the cleaning chamber, the bracket forming a gap between itself and the inner side wall of the cleaning chamber, the gap selectively seating an elastomer fastener protruding downward from a nut plate.

19. The laser ablation storage system according to claim 1, wherein the Class 1M or higher-rated laser includes a Class 4 laser.

20. A debris storage system, A conduit for delivering pressurized fluid to the cleaning chamber, The outlet connected to the aforementioned conduit, A debris containment system wherein the outlet is positioned to direct the pressurized fluid to substantially cross the internal channel of the cleaning chamber as an air curtain substantially crossing the internal channel of the cleaning chamber, thereby substantially preventing debris on one side of the internal channel of the cleaning chamber from crossing the air curtain to the other side of the internal channel of the cleaning chamber.

21. The debris storage system according to claim 20, wherein the internal channel includes a cylindrical channel, and the outlet includes a hemispherical slot formed in the inner side wall of the cleaning chamber.

22. The debris storage system according to claim 21, wherein the hemispherical slot faces forward of the internal channel, and the air curtain extends substantially horizontally across the internal channel of the cleaning chamber.

23. The debris storage system according to claim 20, wherein the conduit includes a first conduit and a second conduit, the outlet includes a first outlet and a second outlet, each of the first outlet and the second outlet opens into the internal channel, and the internal channel generates a first air curtain and a second air curtain offset from the first air curtain.

24. The debris storage system according to claim 23, wherein the first air curtain and the second air curtain extend so as to cross the internal channel of the cleaning chamber at different angles to each other.

25. The debris storage system according to claim 23, wherein the first conduit includes an upper conduit, the second conduit includes a lower conduit, and each of the upper conduit and the lower conduit includes a slot, the slot having a width of about half the outer circumference of the internal channel of the cleaning chamber.

26. The debris storage system according to claim 20, wherein the air curtain extends substantially horizontally across the internal channel and toward a debris removal chamber that is in fluid communication with the internal channel.

27. Furthermore, the debris storage system according to claim 26 further includes at least one of a HEPA filter and a carbon filter positioned within the debris removal chamber to absorb debris.

28. Furthermore, the debris storage system according to claim 26 includes an air pressure sensor positioned in either the cleaning chamber or the debris removal chamber.

29. The debris storage system according to claim 20, wherein the outlet is positioned at a certain angle with respect to the internal channel, and the air curtain extends at a certain angle with respect to the internal channel so as to cross the internal channel.

30. The debris storage system according to claim 20, wherein the outlet includes a substantially elongated slot, the elongated slot is formed from a tubular bracket extending through an internal channel of the cleaning chamber.

31. The debris storage system according to claim 30, wherein the elongated slot positions the air curtain so that the air curtain flows at least partially vertically through the internal channel of the cleaning chamber.

32. The debris storage system according to claim 31, wherein at least a portion of the vertical flow of the air curtain is in the opposite direction to the movement of debris toward the laser chamber coupled to the cleaning chamber.

33. An adhesive dispenser system, The frame to which the drive unit is attached, The drive unit includes a screw that is operated in a screw-like manner, The screw engages with a carrier unit that is slidable relative to the frame and has at least one collet assembly rigidly coupled to the carrier unit. An adhesive dispenser system in which the at least one collet assembly includes a piston collet, the piston collet is selectively slidable with a piston head, and is operable to dispense liquid in small amounts from a cartridge when the drive unit operates the screw in a first direction, and is operable to reduce liquid "leakage" when the drive unit operates the screw in a second direction opposite to the first direction.

34. The adhesive dispenser system according to claim 33, wherein the drive unit is operable to move the screw at a speed that dispenses the liquid in increments of less than 0.1 grams.

35. The adhesive dispenser system according to claim 33, wherein the adhesive dispenser system is coupled to a transportable roller station.

36. The adhesive dispenser system according to claim 33, further comprising a support bracket having an extension, the extension being sized to receive a dispensing needle at a spaced distance from the frame, the support bracket being selectively adjustable relative to the frame by an elongated channel, and the elongated channel being lockable to the frame by a positioning pin located therein.

37. The adhesive dispenser system according to claim 33, wherein the piston collet is terminated with an outward flaring mandrel, and the mandrel is sized to friction fit with the piston head.

38. The adhesive dispenser system according to claim 33, wherein the at least one collet assembly comprises a pair of collet assemblies, each of which comprises a piston collet, the piston collets being selectively slidable with a piston head that is operable to dispense adhesive in small amounts from a dual cartridge assembly.

39. The adhesive dispenser system according to claim 38, wherein each of the piston heads has a different size from the others.

40. Furthermore, the adhesive dispenser system according to claim 33, further comprising at least one feedback sensor coupled to the drive unit in order to provide real-time sensing feedback regarding the viscosity of the adhesive.

41. The adhesive dispenser system according to claim 40, wherein the at least one feedback sensor includes a force feedback sensor that measures the current or voltage of the drive unit in real time.

42. Furthermore, the adhesive dispenser system according to claim 33 includes a camera positioned to image the adhesive dispensed in small quantities from the cartridge.

43. Furthermore, the adhesive dispenser system according to claim 33 includes a quick-release mechanism for removing the piston collet from engagement with the cartridge in one step.

44. The adhesive dispenser system according to claim 43, wherein the quick-release mechanism includes a slide bracket having a stepped portion, the stepped portion being actuated to compress a spring from a first normal extended position to a second compressed position that pulls the piston collet away from engagement with the piston head.

45. The adhesive dispenser system according to claim 44, wherein the slide bracket includes a pull-back channel having a slide pin, the slide pin restricts the movement of the slide bracket relative to the carrier unit to a predetermined distance.

46. Furthermore, the adhesive dispenser system according to claim 44, further comprising a stop coupled to the carrier unit, the stop being positioned to terminate the rearward movement of the slide bracket relative to the carrier unit by a predetermined distance.

47. The adhesive dispenser system according to claim 33, wherein the frame includes a thermal enclosure, the thermal enclosure having a cooling element or heating element adjacent to a quick-change carrier.

48. A quick-change cartridge system, Frame and, Includes a liquid storage cartridge, The frame includes a pair of outwardly extending locator pins, the locator pins having a size and shape for selective sliding engagement with a slotted housing of a dispenser unit. The liquid storage cartridge has a size and shape for selective sliding acceptance into the opening of the frame and / or removal from the opening of the frame when the frame is removed from the dispenser unit. A quick-change cartridge system in which the liquid storage chamber can be positioned forward within the frame, communicating with a small dispensing outlet and fluid when the frame engages with the dispenser unit.

49. The quick-change cartridge system according to claim 48, wherein the frame includes a front hole, the front hole having a size and shape smaller than the liquid storage cartridge and larger than the small dispensing outlet.

50. The quick-change cartridge system according to claim 48, wherein the locator pin includes a bolt extending outward from the frame, the bolt having a shank portion that is long and smooth enough for a sliding reception into the slotted housing in order to position the head portion of the bolt outside the slotted housing.

51. The quick-change cartridge system according to claim 50, wherein the slotted housing includes a pair of externally accessible L-shaped receiving channels, the L-shaped receiving channels being wider than the width of the shank portion and narrower than the width of the bolt head portion.

52. The quick-change cartridge system according to claim 51, wherein the externally accessible L-shaped receiving channel includes an enlarged chamfered opening upper part accessible for drop-in receiving of the frame of the slotted housing.

53. The quick-change cartridge system according to claim 48, wherein the liquid storage cartridge includes an outwardly extending base plate, the base plate being at least partially larger than the opening for coplanar engagement with the frame when the liquid storage cartridge is mounted to the frame.

54. The quick-change cartridge system according to claim 48, wherein the liquid storage cartridge comprises a pair of liquid storage cartridges, each of which is in fluid communication with a cap having an outlet port, the outlet port being selectively coupled to a dispensing outlet including an inlet for a static mixer extending outward from the frame.

55. The quick-change cartridge system according to claim 48, wherein the liquid storage cartridge includes at least one rear receiving slot, the rear receiving slot having a size and shape for selective engagement with the collet assembly of the dispenser unit.

56. This is a small-scale adhesive dispensing feedback method, The steps include: activating a drive unit to dispense a fixed amount of adhesive at a desired flow rate, A step of monitoring one or more dispensing characteristics related to the amount of adhesive dispensed in small amounts, The steps include cross-referencing the one or more of the aforementioned fractional dispensing characteristics with a set of operating parameters for each of the one or more of the aforementioned fractional dispensing characteristics, A method comprising the step of adjusting the desired flow rate of the constant amount of adhesive using the drive unit if the one or more of the dispensing characteristics deviate from any of the set of operating parameters.

57. Furthermore, the step of reversing the drive unit, The steps include: pulling back the piston head inside the liquid storage cartridge, which is operated by the drive unit that dispenses the adhesive in small amounts from the outlet tip; The adhesive dispensing feedback method according to claim 56, comprising the step of generating negative pressure at the outlet tip in order to stop dispensing the adhesive in small amounts and control leakage at the outlet tip.

58. Furthermore, the adhesive dispensing feedback method according to claim 56, further comprising the step of reading the temperature of one or more liquid compounds in the liquid dispensing cartridge.

59. Furthermore, the adhesive dispensing feedback method according to claim 58, further comprising the step of changing the temperature of the one or more liquid compounds in the liquid dispensing cartridge using a heater or cooler.

60. Furthermore, the adhesive dispensing feedback method according to claim 56, further comprising the step of controlling the viscosity of the adhesive.

61. Furthermore, the step of sliding a carrier unit having a pair of collet assemblies so as to engage with each of a pair of cartridges positioned in a stationary relationship with the carrier unit, The adhesive dispensing feedback method according to claim 56, comprising the step of dispensing liquid from each of the set of cartridges into a static mixer in order to form an adhesive.

62. Furthermore, the adhesive dispensing feedback method according to claim 61, further comprising the step of engaging the piston collet in each of the collet assemblies with the respective piston heads that are fluidly related to each of the set of cartridges.

63. The adhesive dispensing feedback method according to claim 61, wherein the adjustment step includes changing the rotational speed of a screw that is operated to slide the carrier unit by the drive unit.

64. The adhesive dispensing feedback method according to claim 56, wherein the monitoring step includes sensing the viscosity of the adhesive being dispensed and determining whether the viscosity is below a threshold or above a threshold.

65. The adhesive dispensing feedback method according to claim 56, wherein the monitoring step includes sensing the current or voltage of the drive unit in real time and determining whether the current or voltage is less than a threshold or greater than a threshold.

66. The adhesive dispensing feedback method according to claim 56, wherein the monitoring step includes measuring the ambient temperature or the temperature of the adhesive.

67. The adhesive dispensing feedback method according to claim 56, wherein the monitoring step includes measuring the one or more dispensing characteristics in real time or in discrete time increments.

68. The adhesive dispensing feedback method according to claim 56, wherein the monitoring step includes observing the adhesive with a camera.

69. A protective lens holder, Frame and, Includes the handle, The frame has a forward-positioned receiving channel, the size and shape of which the receiving channel is configured to selectively receive a protective lens into the receiving channel when the frame is in a first open position, and is movable to a second position in which it slides into the inner side wall of the cleaning chamber and locks the protective lens in cooperation with the inner side wall. The handle extends outward from the frame on the side opposite to the receiving channel, and the size and shape of the handle are configured to allow manual operation on the outside of the outer side wall of the cleaning chamber, thereby forming a protective lens holder.

70. The protective lens holder according to claim 69, wherein the protective lens is selectively replaceable, and the protective lens holder is selectively reusable together with the cleaning chamber.

71. The protective lens holder according to claim 69, wherein the receiving channel includes a substantially horizontal open slot for selectively inserting and removing the protective lens into the receiving channel in the first open position.

72. The protective lens holder according to claim 69, wherein the handle includes a pair of arc-shaped recesses facing opposite directions, the arc-shaped recesses thereby improving manual operation of the protective lens holder outside the outer side wall of the cleaning chamber.

73. The protective lens holder according to claim 69, wherein the protective lens includes a light-transmitting protective lens.

74. A debris removal system, Outlet conduit and The port of the aforementioned outlet conduit, Includes the controller, The outlet conduit is in fluid communication with the cleaning chamber, and the debris removed from the substrate is located within the cleaning chamber. The port is coupled to a pressure sensor and is in fluid communication with it in order to measure the pressure in the outlet conduit in real time. A debris removal system comprising a controller coupled to a pressure sensor, which communicates with a laser configurable to generate a beam into the cleaning chamber to remove debris from the substrate, and which is configurable to deactivate the beam in response to a pressure loss in the outlet conduit measured by the pressure sensor.

75. Furthermore, the debris removal system according to claim 74, further comprising an inlet port for selectively receiving a pressurized fluid that generates at least a partial vacuum in the outlet conduit relative to the cleaning chamber.

76. The debris removal system according to claim 75, wherein the inlet port is connected to a pneumatic air pump.

77. Furthermore, the debris removal system according to claim 75 further includes a HEPA filter or carbon filter positioned within the outlet conduit for filtering the debris.

78. A method for replacing a quick-change cartridge, The steps include sliding the carrier to disengage it from the frame of the dispensing unit, The steps include removing the liquid storage cartridge from the carrier via the access port, The steps include inserting a new liquid storage cartridge into the carrier through the access port, A method comprising the step of reinserting the carrier supporting the new liquid storage cartridge into the frame of the dispensing unit.

79. The method according to claim 78, further comprising the step of disengaging the liquid storage cartridge from the slide unit of the dispensing unit.

80. The step of removing the liquid storage cartridge from engagement is: A step of moving an externally accessible slide bracket rearward relative to the slide unit, The steps include compressing a tension spring, normally positioned forward, within a retraction channel by engaging a washer located at one end of the tension spring with an inwardly protruding stepped portion, The method according to claim 79, comprising the step of disengaging and retracting the flaring mandrel of the piston collet from its friction fit engagement with the piston head associated with the liquid storage cartridge in response to the compression of the tension spring.

81. The method according to claim 80, wherein the compression step includes compressing the tension spring using an intermediate protruding step positioned between the coils of the tension spring.

82. The method according to claim 80, wherein the moving step includes a step of ending the rearward movement of the slide bracket using a stop integrated with the frame or a stop positioned in a pull-back channel formed in the slide bracket.

83. The method according to claim 78, further comprising the step of moving a pair of locking pins, the pair of locking pins projecting outward from the carrier through an L-shaped channel formed in the frame so as to be accessible from the outside.

84. The method according to claim 83, wherein the outwardly projecting pair of locking pins includes a bolt, the bolt having a shank portion movable within the L-shaped channel and a head portion larger than the L-shaped channel and positioned outside the L-shaped channel.

85. The method according to claim 83, further comprising the step of locking a new liquid storage cartridge into the front slot of the L-shaped channel.

86. The method according to claim 78, wherein the reinsertion step includes the step of re-engaging the slide unit with the piston head associated with the new liquid storage cartridge by tapping a screw, rotating an externally accessible knob, or retracting the piston head to engage.

87. A method for cleaning a surface, A step of surrounding a laser chamber that integrates a Class 1M or higher-rated laser, The steps include positioning the substrate in an ablation chamber coupled to the laser chamber and aligned with a laser of class 1M or higher, The steps include moving the header between a first position that exposes the interior of the ablation chamber in order to place the substrate in the ablation chamber, and a second position that closes the interior of the ablation chamber and, in cooperation with the laser chamber, forms an enclosure capable of operating a Class 1 certified laser, The steps include generating a beam with a laser of class 1M or higher, A method comprising the step of bringing at least a portion of the substrate into contact with the beam to clean debris from the substrate.

88. The method according to claim 87, further comprising the step of picking and placing the substrate in the header.

89. The method according to claim 87, further comprising the step of arranging the substrate at an angle between 90 and 180 degrees with respect to the beam.

90. The method according to claim 87, further comprising the step of inserting a protective lens between the laser chamber and the ablation chamber and substantially perpendicular to the beam.

91. The method according to claim 90, wherein the step of generating the beam includes the step of sending the beam through the protective lens to contact the substrate.

92. The method according to claim 90, further comprising the step of activating a proximity sensor in response to the insertion of the protective lens or the formation of the enclosure on which a Class 1 certified laser can be operated.

93. The method according to claim 90, further comprising the step of bringing the front slot of the protective lens holder into contact with the inner side wall so as to lock the protective lens within the protective lens holder.

94. The method according to claim 87, further comprising the step of sandwiching the base material between the upper sealing member and the lower sealing member of the header.

95. Furthermore, the step includes correcting the orientation of at least a portion of the beam with a mirror, The method according to claim 87, wherein the contact step includes ablating the substrate simultaneously at two different beam angles.

96. The method according to claim 95, further comprising the step of pivoting the mirror about at least one plane.

97. The method according to claim 96, wherein the pivoting step includes repositioning the mirror around a ball-socket joint.

98. The method according to claim 87, further comprising the step of splitting the beam with a prism before the step of bringing it into contact.

99. The method according to claim 87, further comprising the step of discharging the debris from the cleaning chamber.

100. The method according to claim 99, wherein the discharge step includes pressurizing the enclosure and forming a vacuum at an outlet port for discharging the ablated debris.

101. Furthermore, the step of measuring the pressure difference between the cleaning chamber and the outlet port, The method according to claim 100, comprising the step of deactivating the beam when the pressure difference between the cleaning chamber and the outlet port falls below a threshold.

102. Furthermore, the method includes the step of monitoring the enclosure capable of operating a Class 1 certified laser in real time using at least one sensor, The method according to claim 87, further comprising the step of terminating the beam when the enclosure no longer conforms to Class 1 based on real-time feedback from at least one of the sensors.

103. The method according to claim 102, wherein the sensor includes a pressure sensor or an optical sensor.

104. A method for attaching a fastener to a base material, The steps include cleaning the adhesive surface of the fastener and at least a portion of the substrate using a laser, The steps include positioning the cleaned adhesive surface of the fastener near the adhesive dispenser, The steps include applying the adhesive to the bonding surface of the fastener using the adhesive dispenser, A method comprising the step of bonding the fastener to the substrate along an adhesive line formed between the adhesive surface of the fastener and the substrate.

105. The method according to claim 104, wherein the cleaning step includes operating a Class 1M or higher-rated laser in a Class 1 certified laser enclosure.

106. The cleaning step described above is: The steps include opening an ablation chamber coupled with a Class 1M or higher-rated laser, The steps include placing the fastener or the substrate in the ablation chamber, The method according to claim 105, comprising the step of closing the header of the ablation chamber around the fastener or at least a portion of the substrate to be ablated to form a laser enclosure certified as Class 1.

107. Furthermore, the step of generating a beam using the laser, The method according to claim 104, comprising the step of bringing the adhesive surface or at least a portion of the substrate into contact with the beam.

108. The cleaning step described above is: The steps include selecting a fastener that includes a nut plate, The steps include positioning the nut plate with respect to an internal bracket protruding inward from the internal side wall of the cleaning chamber such that the elastomer member extending from the bottom surface of the nut plate is bent away from the laser beam path, The method according to claim 104, comprising the step of ablating the bottom surface of the nut plate using the beam.

109. The method according to claim 108, wherein the ablation step includes a step of rotating the bottom surface of the nut plate relative to the beam while the elastomer member remains away from and bent from the beam.

110. The positioning step described above is: The steps include removing the ablated nut plate from the cleaning chamber, The steps include sliding the elastomer member into the slot of the locator block, The method according to claim 108, comprising the step of bending the elastomer member away from the outlet, while simultaneously aligning the bottom surface of the nut plate near the outlet of the adhesive dispenser.

111. The method according to claim 110, wherein the coating step includes bending the elastomer holder away from the outlet and simultaneously rotating the bottom surface of the nut plate relative to the outlet of the adhesive dispenser.

112. The method according to claim 111, wherein the rotation step includes adjusting the rotational speed of the bottom surface of the nut plate in response to a desired flow rate of the adhesive.

113. The method according to claim 108, wherein the bonding step includes the step of pulling the elastomer member through a hole in the substrate in order to pull the bonding surface of the fastener into the substrate and bond it.

114. A method for storing debris, The steps include sending pressurized fluid into the debris containment chamber, The steps include: dispersing the pressurized fluid as an air curtain across the open inner channel in the debris containment chamber; The steps include preventing at least some of the debris in the debris containment chamber from crossing the air curtain, A method comprising the step of discharging at least some of the pressurized fluid, together with at least some of the debris, out of an outlet port fluid-coupled to the debris containment chamber.

115. The method according to claim 114, wherein the air curtain comprises a pair of air curtains, the pair of air curtains comprising a first air curtain positioned substantially perpendicular to the inner channel and a second air curtain offset by 10 to 90 degrees from a direction perpendicular to the inner channel.

116. The method according to claim 115, wherein the dispersion step includes forming the first air curtain outside a slot formed in at least a portion of the open inner channel of the debris storage chamber.

117. The method according to claim 115, wherein the dispersion step includes forming the second air curtain outside a tubular bracket extending into an open inner channel of the debris containment chamber.

118. The method according to claim 114, further comprising the step of monitoring the real-time pressure inside the debris containment chamber.

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