Laser-Processed Material Odor Reduction via Localized Heating

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Solution Overview

Problem

Laser processing of materials often results in a lingering odor, particularly in porous materials like paperboard, which is undesirable in various applications such as packaging, as it can taint the product's aroma or olfactory characteristics.

Innovation Solution

The method involves heating the laser-processed material to a sufficient temperature to reduce or eliminate the odor, using a combination of laser systems where one laser cuts or scores the material and a second laser applies localized heat to the affected area without cutting, while maintaining the material in a flat position to prevent curling and discoloration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If laser processing is used to cut or score material, then productivity and manufacturing precision are improved, but odor is generated that taints the material

Engineering Contradiction:

Improveproduction speedVSAvoidodor

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent extracts and removes the harmful odor substances from the laser-processed material by directing a stream of inert gas or vapor over the processed surface, causing the odor-causing compounds to volatilize and be carried away from the material

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces an inert atmosphere (such as nitrogen or steam) into the processing zone to displace oxygen and prevent oxidative reactions that generate odor, while also facilitating the removal of volatile odor compounds through the inert gas stream

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

2Object-generated harmful factors

If heating is applied to reduce odor, then odor is eliminated, but material may curl or deform

Engineering Contradiction:

ImproveodorVSAvoidflatness

Core Design Contradiction:

Object-generated harmful factorsVSShape

Solution Approach 1:

The patent applies heating locally only to the laser-processed zones where odor is generated, rather than heating the entire material sheet, thereby eliminating odor while minimizing thermal effects on adjacent areas that could cause curling or deformation

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses controlled partial heating at moderate temperatures for short durations, applying just enough heat to volatilize odor compounds without excessive heating that would cause material deformation or curling

Inventive Principle:

Principle #16Partial or excessive action

3Stability of the object's composition

If conventional die-based systems are used, then material stability is maintained, but device complexity and loss of time increase due to die storage and changeover

Engineering Contradiction:

Improvematerial stabilityVSAvoiddie storage and changeover

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical die-based cutting and scoring system with a laser-based system that uses optical energy to process the material, eliminating the need for physical dies and their associated storage, handling, and changeover operations

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the fundamental processing parameter from mechanical force (die cutting) to thermal energy (laser heating), enabling flexible digital control of cutting patterns without physical tooling changes

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach significantly reduces or eliminates the post-processing odor, preserving the material's chemical composition and moisture content, and maintaining its lay-flat properties, with over 95% odor reduction achieved in various materials tested.

Implementation Method 1

heating the material to a temperature sufficient to substantially reduce the odor

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

a second laser system for producing a second laser beam of a selected wavelength, the second selected wavelength being absorbable by the material sufficient only to heat the material thereby reducing the odor

Methodology Applied

Scientific EffectLaser heating: Laser

Data Source

PatentUS10179378B2Odor reduction in laser processed material with curl reduction

Publication Date: 2019.01.15 PRECO LLC

AI summary

The present invention includes methods for treating laser-processed materials having an odor generated during the laser processing. The present method includes treating the laser-processed materials with heat to dissipate the odor from the material. The laser processed material may be secured to avoid curling during the heating process. The method can also include a cooling step after heating of the laser-processed material. Multiple cycles of heating and cooling may also be performed to substantially reduce or eliminate the odor from the laser-processed material. The invention also includes articles made according to the method and apparatus for producing laser processed materials having substantially reduced odor.