Modular handheld laser material processing system

Abstract

A handheld laser tool system includes a cartridge-based mechanism for replacing protective windows without exposing internal optics to the environment. The cartridge-based mechanism includes a cartridge configured to hold one or more pre-cleaned protective windows and a manual mechanism operable to force out a contaminated window in an optical path and replace it with a clean window from the cartridge. The cartridge is a consumable item pre-loaded with clean windows. The manual mechanism is configured to operate without exposing the internal optics to the environment during the protective window exchange. The cartridge is configured hold multiple pre-cleaned protective windows in a stacked arrangement and individually dispense same.

Description

5117.0019W01MODULAR HANDHELD LASER MATERIAL PROCESSING SYSTEMFIELD OF INVENTION

[0001] The present disclosure relates to handheld laser systems, and more particularly to a modular laser system with a handheld laser tool for material processing having interchangeable components and programmable features for improved functionality and user experience.BACKGROUND

[0002] Handheld laser material processing systems, particularly handheld laser welding tools, have gained popularity in recent years due to their portability, precision, and ability to perform high-quality welds in various applications. These systems typically consist of a portable laser radiation generation and control unit, a handheld laser tool, sometimes referred to as a “torch,” and connecting cabling between the handheld laser tool and the laser power and control unit. As laser technology has advanced, the average power of laser diodes has increased while their cost per watt has decreased, making higher-power laser systems more accessible to smaller machine shops and individual users.

[0003] Traditional laser welding equipment often requires large, stationary setups that limit flexibility in welding operations. Handheld laser welding systems address this limitation by providing a more compact and mobile solution. However, existing handheld systems may face challenges in terms of ergonomics, ease of use, and adaptability to different material processing tasks.SUMMARY

[0004] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0005] As the cost of laser radiation generation has decreased and handheld laser processing tools have become less expensive, the inventors have recognized opportunities for integrating improved functionality, efficiencies, and modularities into handheld laser tools that enhance the user experience, facilitate safe practices, and provide for improved material processing results, particularly associated with handheld laser welding.5117.0019W01

[0006] A conventional handheld laser material processing system, particularly a laser welding system, requires several discrete connections at the handheld laser tool, first the laser fiber, also a process gas connection, and electrical connections associated with the on / off trigger on the handheld tool. In embodiments, an umbilical cord containing the laser fiber, a process gas conduit, and electrical wiring for power, control, and communications, has a unitary connector at a distal end allowing simultaneous connection of the laser fiber, process gas conduit, and electrical wiring to the handheld laser tool. Alignment and guide structure on the umbilical cord connector and the handheld laser tool facilitate a reliable easy-to-make connection.

[0007] Handheld laser welding and other handheld laser material processing require that the optics system associated with the transmission of laser energy by the handheld laser tool are essentially contamination free. The impact of the laser radiation on a workpiece can generate debris that is launched from the workpiece and that enters the laser beam exit of the handheld laser tool and is deposited on the most distal optic component in the handheld laser tool. As the contamination level of that most distal optic component increases, the functionality of the handheld laser tool is impeded. With sufficient contamination of the most distal optic component, overheating and damage to the handheld laser tool may result. Generally, handheld laser tools utilize a replaceable protective window as the most distal optic component. In conventional handheld laser tool, the protective window seats in a recess and requires partial disassembly of the distal end of the handheld laser tool to replace the protective window. The inventors have recognized inefficiencies and issues associated with this process. One issue is that the user, the operator of the handheld laser tool, does not have certainty or adequate indication as to when the protective window needs to be replaced. Additionally, replacing the protective window can be tedious involving disassembly of a portion of the handheld laser tool with tools, manually, with fingers, removing the contaminated protective window from the region in which it is seated, and inserting manually, with fingers, a replacement protective window into the protective window seat, and then reassembling the handheld laser tool. In a shop environment, where there is welding and / or other laser material processing, the risk of the new protective window being contaminated by the user disassembly and manual removal and replacement exists. Additionally, the inventors have observed and recognized that the optics system components behind the protective window may be exposed to contaminants during the manual replacement process, particularly if the protective window is not immediately reinstalled. In identifying these issues, the inventors have now developed systems, methods and apparatus that allows for identifying when a protective window needs to be replaced and5117.0019W01 replacing the window while minimizing the risk of subjecting the optics system to contamination during the replacement process. According to aspects of the present disclosure, a handheld laser tool, has a protective window receiving region with a protective window seat, the protective window receiving region has an insertion port on one side of the receiving region and an ejection port on a different side of the receiving region with a protective window travel path or travel slot extending therebetween. The In embodiments, a contaminated protective window may be ejected without disassembly of the handheld laser tool and without manually touching the contaminated protective window, provided. In embodiments, a replacement protective window may inserted into the receiving region for seating in the protective window seat, without disassembly of the handheld laser tool and without manually touching the replacement protective window. In embodiments, a contaminated protective window may be ejected out the ejection port of the receiving region while a replacement protective window is inserted into the receiving region, without disassembly of the handheld laser tool. In embodiments, a mechanism is provided for the ejection of the contaminated protective window and / or the insertion of a clean protective window. In embodiments, the handheld laser tool includes a cartridge-based mechanism for replacing protective windows without exposing internal optics to the environment. The cartridge based mechanism includes a cartridge that holds one or more pre-cleaned protective windows. In embodiments, the cartridge is integrated into the handheld laser tool and operable by a manual, electronic, or pneumatic mechanism configured to eject out a contaminated protective window and replace it with a clean protective window from the cartridge. The cartridge may be a consumable item pre-loaded with one or more clean protective windows.

[0008] In embodiments, a sensor, for example configured as a laser light sensing sensor may be oriented to detect laser light that is deflected from contamination present on the protective window. In other embodiments, a light sensor may be paired with an LED to quantify transparency and / or contamination on a protective window. The sensor connected to a processor such that when a signal correlated with a contamination level is reached, an indication, such as a signal is provided to the user that the protective window needs replacing. In embodiments, the control processor can disable the laser light generator or may limit the laser light generator to a reduced power level.

[0009] Conventionally, electric arc welders and gas welders require operators to walk away from a workpiece or welding region to approach a control unit to adjust operational parameters, such as voltage, process gas flow, welding gas flow, etc. Welders are accustomed to such stepping away from the welding site for welding equipment adjustments of operational5117.0019W01 parameters. The inventors have observed that when utilizing a handheld laser tool, certain operational parameters can be adjusted at the workpiece or weld site by utilizing controls on the handheld laser tool. Additional preprogrammed sets of operational parameters suitable for example for welding certain materials, can selected and switched to at a user interface positioned on the handheld laser tool.

[0010] The foregoing general description of the illustrative embodiments and the following detailed description thereof are merely exemplary aspects of the teachings of this disclosure and are not restrictive.BRIEF DESCRIPTION OF FIGURES

[0011] Non-limiting and non-exhaustive examples are described with reference to the following figures.

[0012] FIG. 1 is a conceptual view of a handheld laser welding system and a work piece.

[0013] FIG. 2 is a conceptual perspective view of the handheld laser tool FIG. 1 performing a weld on the workpiece.

[0014] FIG. 3 is a perspective view of the handheld laser tool of FIG. 2.

[0015] FIG. 4 is side view of the handheld laser tool of FIG. 2.

[0016] FIG. 5 is a cross sectional view of the handheld laser tool of FIG. 2 illustrating a protective window receiving region and seat.

[0017] FIG. 6 is a cross sectional and exploded view illustrating a protective window seated in the protective window receiving region and a retainer for securing the protective window in a seated position.

[0018] FIG. 7 is a side elevational view of a handheld laser tool with an upper port for receiving protective windows.

[0019] FIG. 8 is a side elevational view of a handheld laser tool with a side port.

[0020] FIG. 9 A is a side view of the handheld laser tool of FIG. 8, taken from the side opposite that of FIG. 8.

[0021] FIG. 9B is a side view of a handheld laser tool.

[0022] FIG. 9C is another view of a handheld laser tool.

[0023] FIG. 10A is a conceptual perspective view of a handheld laser tool with a slot extending from an top side to a lower side and with a replacement window for insertion.

[0024] FIG. 10B is a conceptual perspective view of the handheld laser tool of FIG. 10A illustrating protective window module being pushed out of the handheld laser tool.5117.0019W01

[0025] FIG. 11 A is a conceptual perspective view of a handheld laser tool with a revolver cartridge with protective windows.

[0026] FIG. 1 IB is a conceptual perspective view of the handheld laser tool of FIG. 11 A with a portion cut away.

[0027] FIGS. 12A through 12F are conceptual diagrams illustrating an example handheld laser handheld laser tool of a modular handheld laser system.

[0028] FIGS. 13 is an exploded view of an example handheld laser tool.

[0029] FIG. 14 is a conceptual diagram illustrating an example controller of a modular handheld laser system.

[0030] FIGS. 15A through 151 are conceptual diagram illustrating a cross-sectional view of a portion of a handheld laser tool during a protective window exchange operation. Insert figs 16-20 (4-8) FIG. 4 is a conceptual diagram illustrating an example perspective view of a torch with a protective window cartridge.

[0031] FIG. 16 is a conceptual diagram illustrating an example cross-sectional view of the torch showing internal optical components.

[0032] FIG. 17 is a conceptual diagram illustrating an example cross-sectional and exploded view of a protective window receiving region.

[0033] FIG. 18 is a conceptual diagram illustrating an example side elevational view of a torch.

[0034] FIG. 19 is a conceptual diagram illustrating an example side elevational view of a torch in an exploded configuration.

[0035] FIG. 20 is a exploded view of a handheld laser tool in accord with embodiments.

[0036] FIG. 21 is an exploded view of a nozzle assembly and chassis with a nozzle assembly interface.

[0037] FIG. 22 is a perspective view of a handheld laser with nozzle assembly components.

[0038] FIG. 23 is a cross sectional view of the forward portion of a handheld laser tool with a nozzle assembly and protective window cartridge connected thereto.

[0039] FIG. 24 is cross-sectional view of a nozzle assembly connected to a handheld laser toot at the nozzle assembly interface and with a gas manifold providing a protective lens seat.

[0040] FIG. 25 is a cross-sectional view of a nozzle assembly connected to a handheld laser tool at the nozzle assembly interface and with a gas manifold and gas profiler providing a laminar flow of gas in the lumen of the nozzle assembly.5117.0019W01

[0041] FIG. 26 is a cross sectional view of a nozzle assembly connected to a handheld laser tool at the nozzle assembly interface and with a gas manifold and gas profiler providing a gas flow in the lumen and a gas flow about the exterior of the nozzle tube.DETAILED DESCRIPTION

[0042] The following description sets forth exemplary aspects of the present disclosure. It should be recognized, however, that such description is not intended as a limitation on the scope of the present disclosure. Rather, the description also encompasses combinations and modifications to those exemplary aspects described herein.

[0043] The present disclosure provides a modular handheld laser system designed to enhance user experience and operational efficiency. Referring to FIGS. 1 and 2, a material processing laser system 100 has a laser power and control unit 104, a handheld laser tool 106, and an umbilical cord 108 connecting the two at a removable connection 110 at the handgrip portion 112 of the handheld laser tool. The handgrip portion 112 joins to a body portion 114 with a forward laser discharge end 115. A nozzle 116 is removably attached at the forward discharge end 115. The laser power and control unit 104 has a laser energy generation source 120, a controller 121, a coolant system 122, a process gas control system 123 and a user interface 124 in the form of controls, indicators, and / or a touchscreen, for example. The laser power and control unit may be connected to a process gas tank with valving in the power and control unit to control the process gas to the handheld tool. A workpiece 124 may be connected to the laser power and control unit by way of a conductive wire 126 such that a complete closed circuit is made with the nozzle contacting the workpiece for assurance that the laser energy is directed toward the workpiece. Handheld laser tool Material processing laser systems are disclosed in U.S. Patent Publications: US 2024 / 0286220, US 2024 / 0009758, and US 2024 / 0173755, owned by the owner of this application. Said patent publications are incorporated by reference herein for all purposes.

[0044] In FIG. 2, the handheld laser tool 106, configured as a welder, is illustrated in an operational mode with laser beam 120 emitted from the laser discharge end 115 generating plasma 122 on the work piece 124 as a weld 128 is accomplished.

[0045] Shown conceptually in FIG. 3, the handheld laser tool 106 has an optics system 136 that includes various optical components including a wobble unit 138 having an oscillating mirror 139. The optics system includes a replaceable protective window 134 as the forward most component of the optical system. In embodiments, the laser system 100 includes means 136 for replacement of the protective window that is toolless and does not require disassembly5117.0019W01 of the handheld laser tool. In embodiments, the means for replacement of the protective window 136 includes a cartridge 140 of one or more replacement protective windows and a insertion and removal mechanism 141. Examples of such means are described below. In embodiments the cartridge 140 may be received and retained within the handheld laser as illustrated in FIG. 3 or may be a discrete cartridge utilized to store the protective windows until a replacement of an existing window is performed wherein it then interfaces with the handheld laser tool.

[0046] Continuing to refer to FIG. 3, the handheld laser tool 106 may include temperature sensors, also termed thermosensors, 143 to monitor the temperature of the portions of the tool. The handheld laser tool 106 may also include a sensor 150 to detect the level of contamination on the protective window for assessing the need for replacing the window. Such a sensor may include, for example, an FED that transmits light radiation to the window with an optical sensor measuring reflected light caused by accumulated contamination.

[0047] Referring to FIGS. 4-8, different views of a handheld laser tool 155 with the positioning of an optical system 132 therein with the forwardmost component of the optical system being the replaceable protective window 134. The protective window 134 being generally a sacrificial element of the optical system, collecting debris during material processing operations and preventing debris and other potential contaminants from reaching the other components of the optical system. A means 158 for replacing the protective window 134 includes an insertion port 160 and a discharge port 161 which may be defined by structure in the body portion 114.

[0048] Referring more specifically to FIGS. 7 and 8, in embodiments, the protective window 134 is received in a protective window receiving region 164 and seats on a protective window seat 166. The protective windows 134 may each comprise a central piano lens 179 with a frame 180 on the periphery of the transparent lens. In embodiments the frame has a circular periphery when viewed axially. In embodiments, when viewed axially, the periphery of the frame has a square shape, as illustrated in FIGS. 7 and 8. In the embodiment of FIGS.4- 8, the handheld laser tool has an upper insertion port 160 for receiving replacement protective window, and a lower discharge port 161 for the removal of the used and replaced protective windows. The insertion and discharge ports may have removable covers 164 to keep contaminants out of the interior of the handheld laser tool in-between protective window replacements. The replacement window may be secured in place by a retainer 168 that may pivot toward and away from the protective window seat 166 about an axis 167 and may have a bias toward the seat 166. The retainer may have an externally accessible or externally5117.0019W01 actuatable handles 170, 171 shown conceptually in dashed lines, or may be powered by a solenoid 173, also shown in dashed lines. A pair of shelves 176, 177 on the retainer capture the protective window 134 when seated on the protective window seat 166. When the retainer is rotated rearward as indicated by the arrow 179, the protective window is released from the retainer 168 and may fall out of the discharge port. The protective windows may be retained in the protective window receiving region by a slight interference fit such that as the retainer is retracted, releasing the protective window, a friction fit retains the window in position. Insertion of the replacement protective window may then push the used protective window out of the protective window receiving region to be discharged out the discharge port by gravity.

[0049] Referring to FIG. 9A, a cartridge 182 may hold a plurality of replacement protective windows 185 and have an interface 187 to engage the top 188 of the handheld laser tool 155. A mechanism 190 on the cartridge 182, such as a plunger, may be utilized to inject a replacement protective window 185 into the insertion port 160 to the protective window receiving region 164. The retainer 168, not shown in this view, may be utilized to secure the inserted window on the protective window seat 166.

[0050] Referring to FIGS. 9B and 9C, in an embodiment of a handheld laser tool 192, the insertion port 194 may be laterally positions with respect to the protective window receiving region and with the protective window discharge port 195 positioned on the opposing side of the handheld laser tool 192.

[0051] Referring to FIGS. 10A and 10B, a handheld laser tool 196 has a protective window travel slot 197 extending from an internal receiving region to the exterior 197.1 of the handheld laser tool 196. The protective window may be in a casing 197.4 and a manual tool 197.5 may be utilized to insert the protective window into the travel slot and push a contaminated cartridge 197.8 out of the slot. FIG. 11A and 11B illustrate an embodiment where a circular cartridge 198 with a plurality of windows 198.1 therein may be rotated in the handheld laser tool 198.5 to provide a clean protective window in the laser beam path. The expended windows may remain in the cartridge until the cartridge is replaced.

[0052] FIGS. 12A through 12F are conceptual diagrams illustrating an example handheld laser handheld laser tool 200 (hereinafter, handheld laser tool 200) of a modular handheld laser system. Handheld laser tool 200 is configured to controllably direct laser radiation along an optical path from a laser power and control unit, which is configured to generate the laser radiation, via an umbilical 150 and handheld laser tool 200 to a substrate. Handheld laser tool 200 may be used for various material processing techniques including ablation, cleaning, cutting, welding, and the like. The modular laser system may include various components that5117.0019W01 work together to provide a comprehensive and efficient welding system. Although the components discussed below are primarily described in reference to welding or cleaning processes, it is understood that the components also may be configured for additional or different material processing techniques. In view of the various material processing techniques and operational scenarios implementing such technique, handheld laser tool 200 is designed to be compact and lightweight, making it easy for the user to handle and operate, and further includes various features and components that enhance its functionality and user-friendliness.

[0053] Handheld laser tool 200 includes a distal tip 202 extending from a shaft 204 that is removably engaged by coupling 206 to head unit 210. Collectively, one or more of distal tip 202, shaft 204, and coupling 106 may define a removable nozzle 203. Nozzle 203 may be configured to coupled via coupling 106 to head unit 210 by any suitable mechanical coupling such as, for example, a threaded coupling, mechanical fasteners, a chuck coupling, a twist-lock coupling, a quick-release coupling, or the like. By enabling removal of nozzle 203, handheld laser tool 200 may facilitate use of various nozzles 203, such as nozzles having larger or smaller openings to accommodate different wobbles or two-axis wobbles or nozzles configured for different operational modes such as welding or cleaning.

[0054] Head unit 210 includes a chassis defining a portion of a pistol grip 212 and supporting a shell 225 and lever 222. Head unit 210 supports internal optics including, but not limited to, a focus lens 264 and galvanometer 240 that includes a mirror 242, an electric motor 244, and electrical contacts 246. Head unit 211 is configured to couple to an umbilical 250 and direct laser radiation down a laser path 260 traversing a collimating lens 262, focus lens 264, and protective window 266, and emitted from distal tip 102. Material processing techniques are monitored by processing circuitry operatively coupled to a sensor suite that may include a protective window photodiode 261, a thermosensor 263, and a plasma sensor 264. Handheld laser tool 200 also includes an exchange module 226 having a cartridge 220, a loader 230, and an ejector 228 configured to retain a protective window 266 and operably coupled to lever 222. Shell 225 supports operational user interfaces such as first trigger 214, second trigger 216, mode selection switch 218, and display 219.

[0055] Head unit 210 is configured to receive a cartridge 220. Cartridge 220 is configured to enable replacement of protective windows without exposing internal optics to the external environment, which may facilitate user operation, reduces risk of contamination of internal optics, prolongs useable life of the internal optics, and / or improves operating efficiency and longevity of handheld laser tool 200. In some examples, cartridge 220 is designed as a5117.0019W01 consumable item pre-loaded with clean protective windows that are sealed from contamination and which can be replaced when all the windows in it have been used.

[0056] As illustrated in the cross-sectional view of FIG. 12B, cartridge 220 extends from a distal portion of head unit 210, such as a lower distal portion below coupling 206. Cartridge 220 is configured to house a plurality of protective windows 221 and is operably coupled to an exchange unit 226 that is housed in head unit 210. Although illustrated as housing eleven protective windows, in other example, cartridge 220 may be configured to house fewer windows, such as one protective window, or between two and ten protective windows, or more protective windows, such as between twelve and twenty protective windows, or more than twenty protective windows. Additionally, the plurality of protective windows 221 may have any suitable arrangement in cartridge 220, such as, for example, freely stacked in any orientation relative to head unit 210, supported by and removably coupled to a feeder tape or wire, arranged on a support defining a common plane, or combinations thereof.

[0057] Each window of the plurality of windows 221 include a fused silica glass pane having two substantially parallel planar surfaces. Optionally, each window of the plurality of windows 211 includes a frame, such as a metal rim, that protrudes from either or both of the parallel planar surfaces of the glass. In some examples, when arranged in cartridge 220, the frame of windows of the plurality of windows 221 are in direct contact, and adjacent parallel planar surface of the glass panes are not in contact. In this way, the frames may prevent scratching or other damage to the parallel planar surfaces of the glass panes.

[0058] Exchange unit 226 is configured displace a first protective window 266 (e.g., a contaminated protective window) from an operating position that is optically coupled to a laser path 260 (also referred to as, an optical path), translate a second protective window 268 (e.g., a replacement protective window) from cartridge 220 to the operating position, and eject first protective window 266 from head unit 210. Exchange unit 226 is configured to operate without exposing the internal optics of handheld laser tool 200 to the environment during the protective window exchange. This design may significantly reduce the risk of contamination and prolong the life of the optics.

[0059] In some examples, exchange unit 226 includes an ejector 228 and a loader 230. Ejector 228 extends along a plane substantially perpendicular to laser path 260 and configured to translate both first protective window 266 and second protective window 268 along the plane. Ejector 228 is coupled to lever 222 that is operable by a user to actuate exchange unit 226 to replace a protective window. For example, lever 222 may be coupled to and rotatable about pivot 224 in the direction indicated by arrow 223. In some examples, lever 222 may be5117.0019W01 directly coupled to ejector 228 to translate ejector 228 in a generally upward direction as indicated by arrow 227. Alternatively, lever 222 may be coupled to ejector 228 via one or more hinge components. The one or more hinge components may enable ejector 228 to translate more closely to the plane compared to examples where ejector 228 is directly coupled to lever 222.

[0060] In other examples, exchange unit 226 may be configured as a revolver mechanism, operating to displace first protective window 266 and position second protective window 268 via a rotational motion. In yet other examples, exchange unit 226 may include a feeder mechanism configured to displace first protective window 226 and position second protective window 268 via translation of a feeder wire.

[0061] In these ways, exchange unit 226 may be designed to allow the user to replace the protective window quickly and easily, without requiring any special tools or technical skills. The user may simply operate exchange unit 226 to eject the contaminated window and insert a clean window from the cartridge into the optical path of handheld laser tool 200. This design may enhance the user-friendliness and operational efficiency of the handheld laser tool.

[0062] Head unit 210 includes a pistol grip 212 supporting a first trigger 214 and a second trigger 216, a optional mode selection switch 218, and an optional display 219, each of which may be configured to control, by a user, an operation of handheld laser tool 200. In some examples, one or more of first trigger 214, second trigger 216, mode selection switch 218, and display 219 may be user configurable through a web application, a mobile application, or at the laser power and control unit. The user configurability of these features may facilitate workflow efficiency by eliminating the need for the user interface with the laser power and control unit, which could be several meters away, to change selected operational parameters.

[0063] First trigger 214 and second trigger 216 may include a single-stage digital trigger, a multi-stage digital trigger, an analog trigger, or a trigger configured to combine selected functionalities of both an analog trigger and a digital trigger by way of hardware, software, or both. In some examples, a user may configure one of first trigger 214 and second trigger 216 to control an arming of handheld laser tool 200 for operation and to begin a flow of process gas and the other of first trigger 214 and second trigger 216 to control power of the laser, e.g., when initiating a welding operation. Other examples of operational parameters may include, for example: controlling by first trigger 214 a wire feed rate, a wobble frequency, a wobble amplitude, or the like; and controlling by second trigger 216 variable power levels within a preselected range via a multi-stage trigger. Such modularity of first trigger 214 and second trigger 216 may provide unique benefits in welding operations, cleaning operations, or both,5117.0019W01 including, but not limited to, utilizing an analog signal from first trigger 214 and / or second trigger 216 to control, at least in part, an output power of the laser, a pulse frequency, a wobble frequency, a wobble amplitude or shape, a process gas flow rate, a wire feed rate, or the like. In this way, handheld laser tool 200 may be user programmable to improve control over a welding or cleaning process.

[0064] Mode selection switch 218 may include a physical switch, such as a toggle switch, push button switch, rocker switch, or the like, or a soft button (e.g., integrated with a touchscreen of display 219). Although illustrated as being positioned on a side of handheld laser tool 200, in other example, mode selection switch may be positioned near or on other features of handheld laser tool 200, such as a rearward facing portion of handheld laser tool 200, adjacent or extending from one of triggers 214, 216, or the like. In some examples, a user may select an operational mode of handheld laser tool 200 via mode selection switch 218. For example, a toggle switch configuration of mode selection switch 218 may include a first position for a tack weld mode and a second position for a straight-line weld mode.

[0065] Display 219 may include any suitable visual interface and, optionally, a touchscreen display to receive user input. Display 219 output may user configurable to provide relevant information to a user, such as, for example, laser power or wobble amplitude (as indicated in FIG. 12D). When including a touchscreen, a graphical user interface (GUI) of display 219 may be further configurable to select and / or position one or more soft buttons on display 219.

[0066] Additionally, or alternatively, handheld laser tool 200 may include one or more status lights configured to output visual signals indicative of selected operational parameters or handheld laser tool status indicators. The one or more status lights may be located on head unit 210, integrated with or adjacent display 219, or the like to provide the user with visual feedback on the current operation mode. The status lights may illuminate, pulse, or change color to indicate the selected operation or handheld laser tool status. For example, the status light may illuminate a first color (e.g., green) when in a weld mode and a second color (e.g., orange) when in a cleaning mode. As a further example, the status light may pulse when a handheld laser tool status is armed and ready to emit the laser and the status light may remain solid when emitting the laser.

[0067] The configurability of one or more of first trigger 214, second trigger 216, mode selection switch 218, and display 219 allow the user to quickly and easily switch between different welding operations, improving the workflow efficiency, and productivity of the welding process.5117.0019W0110068] FIG. 13 is a conceptual diagram illustrating an exploded view of an example handheld laser tool 300. Handheld laser tool 300 may be the same as or substantially similar to handheld laser tool 200 described above in reference to FIGS. 12A through 12D, except for the differences described herein. For example, handheld laser tool 300 includes distal tip 302, shaft 304, and coupling 306 defining nozzle 303, couplable to a head unit 310 having a chassis 311 defining a portion of a pistol grip 312 and supporting a shell 325 and lever 322. Chassis 311 may further support internal optics including, but not limited to, a focus lens 364 and galvanometer 340 that includes a mirror 342, an electric motor 344, and electrical contacts 346. Chassis 311 is configured to couple to an unified termination head 351 of umbilical 350 having a laser fiber 352, process gas ports 356, and electrical couplings 354. Handheld laser tool 300 also includes an exchange module having a cartridge 320, a loader 330, and an ejector 328 configured to retain a protective window 366 and operably coupled to lever 322 via a hinge 321 to translate through an ejector aperture 329 defined by chassis 311. Shell 325 supports operational user interfaces such as first trigger 314, second trigger 316, and mode selection switch 318.

[0069] FIGS. 15A through 151 are conceptual diagram illustrating a cross-sectional view of a portion of a handheld laser tool during a protective window exchange operation.

[0070] In the first view (FIG. 15A), the protective window 566 is in place within the optical path. The cartridge 520 is visible, containing additional protective windows. A spring force arrow 521 indicates the direction of force applied to the cartridge 520.

[0071] The second view (FIG. 15B) depicts initiating the window replacement process. As ejector 528 is moved in the direction indicated by arrow 527, ejector 528 begins to disengage from the loader 530. Loader 530 is urged by loader spring 531 in the direction indicated by arrow 533. A retainer arm 534 is urged by retainer arm spring 540 in the direction indicated by arrow 535. Retainer arm 534 urges retainer arm stop 536 into the next replacement window to retain the next replacement window during the loading process.

[0072] The third view (FIG. 15C) shows ejector 528 disengaged from loader 530.

[0073] As ejector 528 continues to move in the direction indicated by arrow 527, replacement window 568 is urged in the direction indicated by arrow 527 toward contaminated window 566.

[0074] In the fourth view (FIG. 15D), ejector 528 continues translation in the direction indicated by arrow 527. Ejector 528 urges replacement window 568 into contact with contaminated window 568. Contact may only be at the edges of the windows, which protects replacement window 568 from scratches or contact with debris. Loader 530 remains5117.0019W01 disengaged and allows contaminated window 566 to be translated in the direction indicated by arrow 527.

[0075] In the fifth view (FIG. 15E), replacement window 568 continues to urge contaminated window 566 out of ejector aperture. Replacement window 568 contacts seal 567 that retains replacement window in the correct position.

[0076] In the sixth view (FIG. 15F), contaminated window 566 is ejected from the ejector aperture 529 and ejector 528 is in the fully extended configuration. Replacement window 568 is in position and retained by seal 567.

[0077] In the seventh view (FIG. 15G), ejector 528 is urge downward in the direction indicated by arrow 529. Replacement window 568 remains engaged by seal 567.

[0078] In the eight view (FIG. 15H), ejector 528 contacts and engaged loader 530 to urge loader 530 in the direction indicated by arrow 537.

[0079] In the ninth view (FIG. 151), ejector 528 contacts and urges retainer arm 534 in the direction indicated by arrow 539. Retainer arm stop 536 is disengaged from the next replacement window.

[0080] Torch 106 may include a cartridge 140 for storing replacement protective windows. An insertion mechanism 141 may be operably coupled to cartridge 140 to facilitate replacement of protective window 134 without requiring disassembly of torch 106. This configuration may allow for efficient maintenance of optics system 136 while minimizing exposure of internal components to environmental contaminants.

[0081] Referring to FIG. 16, a torch 600 may be configured with a modular design for enhanced functionality and user operation. Torch 600 may include a distal tip 602 extending from a shaft 604. Shaft 604 may be removably engaged by a coupling 606 to a head unit 610. This modular configuration may allow for interchangeable components and simplified maintenance operations.

[0082] Head unit 610 may include a pistol grip 612 that provides an ergonomic grip for user operation. Pistol grip 612 may support a first trigger 614 and a second trigger 616, which may be configured to control various operational parameters of torch 600. In some cases, first trigger 614 and second trigger 616 may be programmable to enable user customization of trigger functions. A mode selection switch 618 may be positioned on head unit 610 to allow users to toggle between different operational modes without requiring access to a separate control unit.

[0083] Torch 600 may include a protective window cartridge 620 extending from head unit 610 and operably coupled to a lever 622 for manual actuation, where a shell 624 with shell5117.0019W01 portion 625 may enclose various components including an exchange module 626 with window ejector 628 and loader 630 configured to facilitate replacement of protective windows while minimizing exposure of internal optical components to environmental contaminants. Protective window cartridge 620 may hold multiple pre-cleaned protective windows in a stacked arrangement, with a replacement window 668 positioned within protective window cartridge 620 for insertion into laser path 660 when protective window 666 requires replacement. This configuration may enable rapid replacement of protective windows without exposing internal optical components to environmental contaminants, and exchange module 626 may include a retainer mechanism that secures protective windows in position along laser path 660, where the retainer may be biased toward a protective window seat to maintain proper positioning of protective window 666.

[0084] Torch 600 may be configured to connect to an umbilical 650 that provides laser energy, electrical power, control signals, and process gas to torch 600. Umbilical 650 may enable communication between torch 600 and a laser power control unit. A nozzle 603 may be positioned at the distal end of torch 600 to direct laser energy toward a workpiece during material processing operations.

[0085] Referring to FIG. 17, torch 600 may include internal optical components arranged along laser path 660. Laser path 660 may traverse through multiple optical elements to direct and condition laser energy for material processing operations. A collimating lens 662 may be positioned along laser path 660 to collimate incoming laser radiation. Laser path 660 may continue through a focus lens 664 that focuses the laser beam toward the workpiece. A protective window 666 may be positioned at the distal end of laser path 660 to protect internal optical components from debris and contamination generated during welding operations.

[0086] Torch 600 may include a galvanometer 640 configured to manipulate the laser beam along laser path 660. Galvanometer 640 may include a mirror 642 that can be positioned to redirect laser energy. An electric motor 644 may be operably coupled to the mirror 642 to provide controlled movement of the mirror 642. Electrical contacts 646 may be provided to supply power and control signals to the electric motor 644. This configuration may enable precise control of laser beam positioning and wobble patterns during material processing operations. Although described as including only one galvanometer, in other examples, torch 600 may include two galvanometers configured to enable dual axis wobble.

[0087] Torch 600 may include a display 619 positioned on head unit 610 to provide visual feedback to users. Display 619 may show operational parameters, system status, or maintenance alerts. In some cases, display 619 may include a touchscreen interface for user5117.0019W01 input and system configuration. Display is positioned to enable a user to visualize both display 619 and distal tip 602 simultaneously to provide visual feedback to users regarding system status, operational parameters, or maintenance alerts.

[0088] Referring to FIG. 18, the torch may be viewed from a front perspective showing distal tip 602, shell 624, pistol grip 612, and the arrangement of external components accessible to users during operation. For example, first trigger 614 and second trigger 616 may be supported by pistol grip 612 in positions that enable intuitive finger placement for trigger actuation, coupling to a mount of a cobot, or both. First trigger 614 and second trigger 616 may be configured as user-replaceable components that can be removed and installed without requiring tools or disassembly of torch 600. Mode selection switch 618 may be positioned on shell 624 in a location that provides easy access for users to change operational modes during welding operations.

[0089] Referring to FIG. 19, torch 600 may be viewed from a rear perspective that shows pistol grip 612, umbilical 650, lever 622, shell 624, mode selection switch 618, and display 619. Mode selection switch 618 may be positioned on shell 624 to allow users to toggle between different operational parameters or welding modes while maintaining a grasp of pistol grip 612. In some cases, mode selection switch 618 may enable switching between tack welding and continuous welding operations without requiring users to access a separate control unit. In some examples, mode selection switch 618 may be modular such that it may be mounted to either a left surface of right surface of shell 624 to accommodate either lefthanded or highhanded operation.

[0090] Referring to FIG. 20, a torch 700 is configured in an exploded arrangement to illustrate the modular construction and user-replaceable components. Torch 700 may be the same as or substantially similar to torch 106 and torch 200, except for the differences described herein. For example, torch 700 includes a distal tip 702 extending from a nozzle tube 704, a threaded retention coupling 706 that removably attaches nozzle tube 704 to a head unit 710, a nozzle 703 positioned at the distal end, a chassis 711 that defines a portion of a pistol grip 712, a first trigger 714 and a second trigger 716 supported by the pistol grip 712, a first contact 715 operably coupled to first trigger 714, a second contact 717 operably coupled to the second trigger 716, a mode selection switch 718 positioned on head unit 710, a cartridge 720 extending from head unit 710, a hinge 721 operably coupling cartridge 720 to a lever, a shell 725 that encloses various components, a window exchange unit 726 couplable to head unit 710, an ejector 728 configured to translate through an ejector aperture 729, a loader 730 positioned to interact with ejector 728, a galvanometer 740 having a mirror 742, an electric motor 744, and5117.0019W01 electrical contacts 746, an umbilical 750 with a unified termination head 751, a laser fiber 752, electrical contacts 754, and process gas ports 756 within unified termination head 751, a focus lens 764 positioned along the optical path, and a protective window 766 positioned at the distal end of the optical path. Additionally, torch 700 includes a sensor suite including, for example, a thermosensor 763 for monitoring temperature conditions within the tool, a plasma sensor 765 configured to detect plasma characteristics during material processing operations, and auxiliary sensors 769 which may include, for example, an IMU, accelerometer, gyroscope, or any other suitable type of sensor configured to monitor operational parameters or system status.

[0091] Torch 700 may include a distal tip 702 extending from a flanged nozzle tube 704 that may be removably engaged by the threaded retention coupling 706 to the head unit 710. The threaded retention coupling or nut 706 has an inward flange for engaging or capturing the central flange of the nozzle tube. A nozzle 703 may be formed by distal tip 702, nozzle tube 704, and threaded retention coupling 706 to direct laser energy toward a workpiece during material processing operations. A focus lens 764 may be positioned along the optical path to focus laser energy toward the workpiece. A protective window 766 may be positioned at the distal end of the optical path to protect internal optical components from debris and contamination generated during material processing operations. Protective window 766 may be replaceable by way of the methods and apparatuses described herein or otherwise known, including using the cartridge 720 and associated replacement mechanisms, without requiring disassembly of torch 700.

[0092] Referring to FIGS. 20-25, further details are depicted of the nozzle assembly 770. A bushing configured as a gas manifold 770 seats in a forward opening 771 of the chassis with the shoulder 773 providing a stop and seat for the gas manifold. The gas manifold, in conjunction with an O-ring 767, provides a seat for the protective window 766. The manifold has O-rings 774 sealing against the interior wall surface of the forward opening 771 and may be secured in place by axial loading provided by an end flange 775 of the flanged nozzle tube 704. An intermediate flange 776 of the nozzle 704 is engaged, through a spacer 777, which may have an L-shape in cross section and may formed of a lower heat conductive material to be an insulator, with the threaded retention coupler 706, that is threadingly engaged with the threads at the forward chassis opening 771. FIG. 24 depicts an embodiment where the chassis providing a shoulder seat 779 for the protective window 766 such that replacing the protective window 766 involves simply manually unscrewing the coupling 706 and removing the flanged nozzle tube 704 and gas manifold, or other bushing in the front opening 771 of the chassis 711,5117.0019W01 and pulling the window 766 out. Replacing the window then could involve simply inserting a replacement protective window therein and reattaching the nozzle assembly.

[0093] Torch 700 may include a process gas delivery system wherein process gas from process gas ports 756 of unified termination head 751 of umbilical 750 may be directed through gas flow passage 783 defined by at least chassis 711 to enter the annulus 781 extending around the gas manifold 770 in the forward opening 771. The gas manifold having radially extending apertures 772 to transfer the gas into the lumen 782 of the nozzle assembly 770. As depicted in FIGS. 23 and 25, the gas manifold may have a gas profiler 784 that is configured to provide a selected gas flow profile (e.g., substantially laminar flow depicted in FIG 25 with a Reynolds number less than 4000 or less than 2300, or turbulent flow depicted in FIG. 24) through nozzle tube 704 to distal tip 702, providing process gas 785 during material processing operations and reducing debris and contamination intrusion into the optical components of torch 700. The gas profiler may be available with different configurations to provide a desired flow rate.

[0094] Referring to FIG. 24, in embodiments, a unitary gas manifold 787 may be provided without a separate gas profiler. The gas manifold may be selected from various gas manifold options to provide desired gas flow characteristics from a supply gas provided to the torch at the handgrip portion. In embodiments, the end flange 775 of the nozzle tubing and any spacers may be slotted or other apertured to provide a gas flow path 788 exterior of the nozzle tube 704, for example coaxially, about the nozzle tube as depicted in FIG. 26. The gas manifold may have axially and radially spaced apertures 772 in particular arrangements and sizes to create desired gas flows such as a turbulent or a spiral gas flow 785 as illustrated in FIG. 24. Such shaping of the gas flow may be advantageous in certain operations such as welding specific materials.

[0095] In embodiments, a handheld laser tool has a nozzle assembly that includes a bushing configured as a gas manifold 770 that provides gas flow in the lumen of the nozzle assembly directly adjacent a protective window seat 768 which is believed to provide an enhanced protection and isolation of the protective window from contaminants from the laser operations.

[0096] In embodiments, an alternately configured coupling 789 may be provided with, for example, a gas dispersion shield 790, or the gas dispersion shield may be a separate component threadingly attached, for example to the nozzle tube, the spacer 777, or the threaded retention coupling 706.

[0097] Torch 700 may be configured to couple to umbilical 750 that provides laser energy, electrical power, control signals, and process gas. Umbilical 750 may include a unified5117.0019W01 termination head 751 that enables simultaneous connection of multiple services, including a laser fiber 752 for transmitting laser radiation, electrical contacts 754 for power and control signals, and process gas ports 756 for delivering process gas to torch 700. The process gas may be comprised of, for example, air, argon, helium, and nitrogen. The process gas may be utilized for shielding the weld puddle, cooling, dispersing the plasma cloud, protecting the handheld laser tool for example by reducing contaminants from entering the nozzle tube.

[0098] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. Accordingly, other implementations are within the scope of the following claims.

Claims

5117.0019W01CLAIMS1. A laser system comprising a handheld laser tool having a body portion and a handgrip portion, with laser radiation entering the handheld laser tool at the handgrip and exiting the handheld laser tool at a forward discharge end of the body portion, The handheld laser tool having an optics system including a removable and replaceable protective window at a forward end of the optics system, the handheld laser tool having a seating position for the protective window, and comprising a retainer for holding the protective window in the protective window seat, the retainer having a retention position where the protective window is secured in the protective window seat and is movable to a release position without disassembly of the handheld laser tool wherein the protective window is removable from the protective window seat.

2. The laser system of claim 1, wherein the retainer is pivotal between the retention position and the release position.

3. The laser system of claim 1 or 2, wherein the retainer is biased toward the retention position thereby clamping the protective window into the protective window seat.

4. The laser system of claim 1 or 2, wherein the retainer is actuatable from the exterior of the handheld laser tool with a manually movable handle without disassembly of the handheld laser tool.

5. The laser system of claim 1 or 2, wherein the handheld laser tool has a discharge port where a protective window seated may be removed from the handheld laser tool by actuation of retainer to move the retainer from the retention position to the release position and without disassembly of the handheld laser tool.

6. The laser system of claim 1 or 2, wherein the handheld laser tool has an insertion port where an unused protective window may be inserted into the protective window seat when the retainer is in the release position and wherein when the unused protective window is in the protective window seat it may be retained therein by the retainer being actuated to the retention position.5117.0019W017. The laser system of claim 1 or 2, wherein the protective window has a transparent lens and a peripheral frame supporting the lens and wherein the retainer only engages the peripheral frame.

8. A laser system comprising a handheld laser tool having a body portion and a handgrip portion, with laser radiation entering the handheld laser tool at the handgrip and exiting the handheld laser tool at a forward discharge end of the body portion, the handheld laser tool having an optics system including a removable and replaceable protective window at a forward end of the optics system, the handheld laser tool having a seating position for the protective window, wherein the protective window is removed from the seating position by pushing the protective window on a peripheral edge with another protective window, whereby the another protective window displaces and replaces the protective window in the seating position.

9. A laser system comprising a handheld laser tool having a body portion and a handgrip portion, with laser radiation entering the handheld laser tool at the handgrip and exiting the handheld laser tool at a forward discharge end of the body portion, the handheld laser tool having an optics system including a removable and replaceable protective window at a forward end of the optics system, the handheld laser tool having a seating position for the protective window, wherein the laser system further comprises a means for removing and replacing the protective window.

10. A laser system including a handheld laser tool comprising: a body containing an optics system including a protective window; a cartridge-based mechanism for replacing the protective window without exposing internal optics to the environment, the cartridge-based mechanism including: a cartridge configured to hold one or more pre-cleaned protective windows; and a manual mechanism operable to force out a contaminated window and replace it with a clean window from the cartridge.

11. The laser system of claim 10, wherein the cartridge is a consumable item pre-loaded with clean windows.5117.0019W0112. The laser system of claim 10, wherein the manual mechanism includes a lever to actuate the mechanism, the lever configured as a cover..

13. The laser system of claim 10, wherein the cartridge is configured to operate in a manner similar to a PEZ dispenser.

14. The laser system of claim 13, wherein the cartridge is configured to hold multiple precleaned protective windows in a stacked arrangement.

15. The laser system of claim 10, wherein the protective window is seated on a gas manifold that is part of a nozzle assembly.

16. The laser system of claim 15, wherein the handheld laser receives and retains the cartridge.

17. A method of replacing a contaminated protective window in a handheld laser tool, the method comprising displacing the contaminated protective window with another protective window without disassembly of the handheld laser tool.

18. The method of claim 17, further comprising releasing a retainer securing contaminated protective window in a window seat.

19. The method of claim 18, further comprising inserting the another protective window from a cartridge of a plurality of protective windows.

20. A laser system comprising a handheld laser tool having a body portion and a handgrip portion, with laser radiation entering the handheld laser tool at the handgrip and exiting the handheld laser tool at a forward discharge end of the body portion, the handheld laser tool having an optics system including a protective window receiving region with a protective window seat at a forward end of the optics system, the handheld laser tool having a insertion port allowing insertion of a protective window into the protective window receiving region and a discharge port allowing removal of a protective window in the receiving region.5117.0019W0121. A laser system comprising a handheld laser tool having a body portion with and a laser beam pathway defining a body portion axis and with a forward laser beam exit, the handheld laser tool having a downwardly facing connection portion including a connection for receiving laser radiation from a laser radiation generation and control unit through a flexible cord, the handheld laser tool having an optics system positioned between the forward laser beam exit and connection portion, the optics system including a wobble generator, a collimator, and a replaceable protective window, wherein the protective window is seated in a protective window receiving region having a protective window seat, the protective window receiving region having a protective window insertion port on one peripheral side of the protective window receiving region, and further having a protective window ejection port on a different peripheral side of the protective window receiving region.

22. The laser system of claim 21, further comprising an ejection mechanism that pushes the protective window in the receiving region out of the receiving region through the ejection port without disassembly of the handheld laser tool and without manually touching the protective window.

23. The laser system of claims 21 or 22, further comprising an insertion mechanism that inserts a replacement protective window through the insertion port into the receiving region of the handheld laser tool without manually touching the replacement protective window.

24. The laser system of claim 21, further comprising a replacement mechanism that ejects the protective window in the protective window receiving region and that inserts a replacement protective window after the protective window is ejected.

25. The laser system of claim 24, wherein the replacement mechanism is manually actuated and manually powered by the user.

26. The laser system of claim 24, wherein the replacement mechanism is electrically powered.

27. The laser system of any of claims 24-26, wherein the replacement mechanism is part of the handheld laser tool.5117.0019W0128. The laser system of claim 21, further comprising a replacement window cartridge that is received by the handheld laser tool at a position proximate to the protective window receiving region, and wherein a replacement protective window from the replacement window cartridge is movable through the insertion port and into the receiving region.

29. The laser system of claim 24, further comprising a replacement window cartridge that is received by the handheld laser tool at a position proximate to the protective window receiving region, and wherein a replacement protective window from the replacement window cartridge is movable into the receiving region by the replacement mechanism after or while the replacement mechanism is ejecting the protective window in the protective window receiving region from the protective window receiving region.

30. The laser system of claim 24, further comprising a replacement window cartridge that is received by the handheld laser tool at a position proximate to the protective window receiving region, the replacement window cartridge and wherein the replacement mechanism slides a replacement protective window from the replacement window cartridge through the receiving port into the receiving region after or while the replacement mechanism is ejecting the protective window in the protective window receiving region out the ejection port.31 The laser system of claim 29 or 30, wherein the cartridge is received by and removably attached to the handheld laser tool at a cartridge receiver on the handheld laser tool, the cartridge attached to the handheld laser tool during operation of the handheld laser tool.

32. The laser system of claim 31, wherein the cartridge is removably attached to the cartridge receiver and is removable after the cartridge is depleted of replacement protective windows and is replaceable with a cartridge filed with replaceable windows.

33. The laser system of any of claims 28-32, wherein the cartridge holds a plurality of replacement protective windows therein, and wherein the cartridge receiver is removably attached to the handheld laser tool adjacent the insertion port at the replacement window receiving region.5117.0019W0134. The laser system of claim 33, wherein the cartridge retains the plurality of replacement protective windows in an axially aligned arrangement.

35. The laser system of claim 33, wherein the replacement mechanism is manually actuated with reciprocating lever on the handheld laser tool.

36. The laser system of claim 33, wherein the replacement mechanism is electrically powered.

37. The laser system of any of claims 21-36, wherein the handheld laser tool comprises a sensor to detect contaminawtion of the protective window seated in the protective window region, and wherein a signal is generated that the protective window should be replaced.

38. The laser system of claim 37, wherein the signal generated provides and alert to the user by way of a visual indication.

39. The laser system of claim 37, wherein the signal actuates an automatic sequence to electronically actuate the replacement mechanism when the handheld laser tool is not in a laser actuated mode.

40. The laser system of any of claims 20 to 39, wherein each protective window comprises a light transmittable inner portion and an outer support frame supporting the light transmittable inner portion at a periphery of the light transmittable inner portion.

41. A laser system comprising a handheld laser tool, the handheld laser tool having a body portion with a forward laser discharge opening and having a rearward handgrip portion extending downwardly from the body portion, the handheld laser tool comprising: an optical system contained therein defining a laser beam path that extends through the handgrip and the body portion and out through the discharge opening, the handheld laser tool further comprising a protective window seat positioned forwardly of a focus lens of the optical system, the handheld laser tool further having a protective window travel slot5117.0019W01 extending from the a top of the handheld laser tool to the protective window seat and to a lower portion of the handheld laser tool, the protective window travel slot having a protective window insertion path on an insertion side of the protective window travel slot and having a protective window discharge path on a discharge side of the protective window travel slot.

42. The laser system of claim 41, further comprising a cartridge with a plurality of clean protective windows stacked therein, the cartridge having a window feed side, and wherein the body of the handheld laser tool is adapted for receiving the cartridge for dispensing a clean window to the protective window travel slot.

43. The laser system of claim 42, wherein the body portion of the handheld laser has a cartridge receiver at a forward end of the body portion and wherein the handheld laser tool retains the cartridge during utilization of the handheld laser tool.

44. The laser system of any of claims 41, 42, or 43, wherein the protective window seat is defined by a component of a removable nozzle assembly extending from a forward end of the body.

45. The laser system of claim 44, wherein the removable nozzle assembly comprises: a tubular member with an O-ring thereon, a proximal end of the bushing having an annular recess with an O-ring therein, the proximal end defining the protective window seat; a flanged nozzle tube, positioned distally of the tubular member with the O-ring; a threaded retention coupling with an inward retaining flange for capturing a flange of the flanged nozzle tube and axially and radially constraining the flanged nozzle tube.

46. The laser system of claim 45, wherein the tubular member with an O-ring is has a forward O-ring and a rearward O-ring engaging a cylindrical wall surface and whereby an annulus is defined between the cylindrical wall surface intermediate the forward and rearward5117.0019W01O-rings, and wherein a gas conduit extends into the annulus through the cylindrical wall surface.

47. The laser system of claim 46, wherein the tubular member with an O-ring has one or more apertures extending through a wall of the tubular member whereby the tubular member is a gas manifold providing gas to a lumen of the nozzle assembly or coaxially about the flanged nozzle tube.

48. The laser system of claim 47, wherein the nozzle assembly is seated in a nozzle assembly threaded recess in a metal chassis in the body of the handheld laser tool.

49. The laser system of claim 47, wherein the metal chassis defines the gas conduit for providing gas that enters the handheld laser tool at the handgrip portion.

50. The laser system of claim 49, wherein the nozzle assembly further comprises a gas profiler that fits within the gas manifold for regulating gas flow levels.

51. The laser system of claim 49, further comprising a plurality of differently configured gas manifolds, and / or a plurality of differently configured gas profilers that communicates with the52. A method of replacing a contaminated protective window with a clean protective window in a handheld laser tool, the handheld laser tool having a body portion with a forward laser discharge opening and having a rearward handgrip portion extending downwardly from the body portion, the handheld laser tool having an optical system therein defining a laser beam path that extends through the handgrip and the body portion and through the discharge opening, the handheld laser tool having a protective window seat in the laser beam path in a protective window receiving region forward of a focusing lens of the optical system the contaminated protective window seated in the protective window seat, the handheld laser tool having a protective window travel slot extending from the a top of the handheld laser tool to a lower portion of the handheld laser tool, the protective window travel slot providing a protective window insertion path on an insertion side of the protective window travel slot and a protective window discharge path on a discharge side of the protective window travel slot, the method comprising:5117.0019W01 a) insertion of the clean protective window into the protective window travel slot at the insertion side; b) moving the protective window along insertion path toward the protective window seat; c) moving the clean protective window to an engagement with the contaminated protective window; d) moving the contaminated protective window along the discharge path by pushing the contaminated protective window with the clean protective window; e) seating the clean protective window in the protective window seat; f) discharging the contaminated protective window out of the discharge side of the protective window slot.

53. The method of claim 52, further comprising providing an axial force to seat the clean protective window on the protective window seat.

54. The method of claim 52, further comprising inserting the clean protective window in a window casing before insertion in the insertion side of the travel slot.

55. The method of claim 52, further comprising utilizing a manual tool to move the clean protective window through the insertion path and to push the contaminated window out of the discharge side.

56. The method of claim 70, further comprising: utilizing a mechanism contained in the handheld laser tool to accomplish the insertion.

57. A method of replacing a contaminated protective window with a clean protective window in a handheld laser tool, the handheld laser tool having a body portion with a forward laser discharge opening and having a rearward handgrip portion extending downwardly from5117.0019W01 the body portion, the handheld laser tool having an optical system therein defining a laser beam path that extends through the handgrip and the body portion and through the discharge opening, the optics system having a protective window seat in the laser beam path in a receiving region forward of a focusing lens, the contaminated window seated in the protective window seat, the handheld laser tool having a protective window travel slot extending from the protective window receiving region to an exterior periphery of the handheld laser tool, the method comprising: a) opening an attached cover on the body of the handheld laser tool with a singular arcuate or linear translational motion thereby opening access to the protective window travel slot whereby the protective window receiving region is open to an exterior of the handheld laser tool; b) releasing a clamping mechanism securing the contaminated protective window on a protective window seat in the handheld laser tool whereby the protective window is unsecured in the protective window receiving region; c) displacing the contaminated protective window from the receiving region to the exterior of the handheld laser tool; d) inserting a clean protective window into the receiving region of the handheld laser tool; e) actuating the clamping mechanism to secure the clean protective window to the protective window seat in the receiving region; and f) closing the attached cover of the handheld laser tool with a singular arcuate or linear motion thereby closing the access path from the receiving region to the exterior of the handheld laser device.

58. The method of claim 60, wherein the step of releasing the clamping mechanism is effectuated by the step of opening of the pivotally or slidingly attached cover and the step of actuating the clamping mechanism is effectuated by the step of closing the attached cover.5117.0019W0159. The method of claim 60 or 61, wherein step a) is accomplished by user grasping the handheld laser tool by one hand and effectuating the opening with the other hand of the user.

60. The method of claim 60, wherein step a) is accomplished by a user using a singular arcuate or linear translational motion occurs without removing any threaded fasteners securing the cover to the body prior to the opening.

61. The method of claim 60, wherein step e) comprises applying a spring force to the clean protective window to secure the clean protective window to the protective window seat.

62. The method of claim 60. wherein the protective window travel slot extends from a top of the handheld laser tool to a lower region of the handheld laser tool providing a window insertion path and a separate window discharge path.

63. The method of any of claims 57 to 62, wherein the handheld laser tool has a window exchange mechanism within an interior of the handheld laser tool, and wherein manually performing steps a) and f) causes the window exchange mechanism to perform steps b), c), d), and e).

64. The method of claim 60, further comprising insertion of a cartridge having a plurality of clean protective windows into a cartridge receiver on the front of the handheld laser tool, whereby a feed end of the cartridge provides clean protective windows to the window exchange mechanism.

65. A method of replacing a contaminated protective window with a clean protective window in a handheld laser tool, the handheld laser tool having a body portion with a forward laser discharge opening and having a rearward handgrip portion extending downwardly from the body portion, the method comprising insertion of a clean protective window into an insertion path of a protective window travel slot; engaging the contaminated protective window with the clean protective window to push the contaminated window out of the handheld laser tool; seating the clean protective window in a protective window seat.

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