Hybrid Laser Surface Processing for Low-Waste Coating Renewal
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Solution Overview
Problem
The removal and application of coatings during routine maintenance in industries like aerospace, defense, and automotive result in the release of hazardous air pollutants and volatile organic compounds due to chemical stripping agents and abrasive media, leading to environmental and cost concerns.
Innovation Solution
A system comprising a controller, a laser applicator, and a coating applicator integrated with a sensor array on a treatment arm, which scans, cleans, and applies coatings using pulsed laser technology and ultrasonic spray coating, minimizing hazardous waste generation by precise control and energy-efficient processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If chemical stripping agents or abrasive media are used for coating removal, then coating removal is effective, but hazardous air pollutants and volatile organic compounds are released
Solution Approach 1:
The patent replaces chemical and abrasive mechanical systems with a laser-based system. The laser applicator uses photothermal and photomechanical effects to remove coatings without chemicals or abrasive media, eliminating hazardous emissions while maintaining effective coating removal through controlled energy application to the component surface
Solution Approach 2:
The patent changes the physical parameters of the treatment process by using laser energy with specific wavelengths, pulse durations, and power levels. By adjusting these parameters, the system achieves effective coating removal through controlled heating and ablation without the harmful emissions associated with chemical strippers or abrasive media
2Manufacturing precision
If spray coating processes are used for coating application, then coating coverage is achieved, but overspray causes hazardous waste and environmental pollution
Solution Approach 1:
The patent replaces the conventional spray coating mechanical system with a laser-induced coating application system. The laser applicator uses focused energy to deposit coating material precisely where needed on the component surface, eliminating overspray and associated hazardous waste while achieving uniform coating coverage
Solution Approach 2:
The system integrates sensing, coating removal, and coating application in a single automated process. The sensor array detects surface conditions, the laser applicator prepares the surface and applies coating, and the entire process is controlled automatically, reducing waste through precise material placement and eliminating the need for separate processing steps
3Object-generated harmful factors
If integrated laser and spray coating system is used, then hazardous waste generation is reduced, but system complexity increases
Solution Approach 1:
The patent merges multiple functions (sensing, coating removal, surface preparation, and coating application) into a single integrated system mounted on a robotic arm. This consolidation reduces hazardous waste through precise laser-based processes while managing complexity by combining components into one coordinated unit rather than separate systems
Solution Approach 2:
The laser applicator serves multiple functions: it removes existing coatings, prepares the surface through controlled heating, and can assist in coating application. This multi-functionality reduces the need for separate equipment, managing system complexity while achieving reduced hazardous waste generation through versatile laser-based processing
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 system reduces hazardous waste generation by over 50% and improves coating quality and efficiency, achieving cost savings and environmental benefits through precise coating removal and application, while reducing worker exposure to chemicals.
Implementation Method 1
cleaning the surface to be treated using the laser applicator
Implementation Method 2
applying a new coating to the surface to be treated using the coating applicator
Implementation Method 3
curing the new coating using the laser applicator
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
Methods and systems for treating components are described. The methods include using a system (200) having a controller (202), a laser applicator (206), a coating applicator (208), and a sensor array (218). The laser applicator (206), the coating applicator (208), and the sensor array (218) are arranged on a treatment arm (204) that is controlled by the controller (202). The method includes scanning a surface to be treated of the component (210) using the sensor array (218), cleaning the surface to be treated using the laser applicator (206), defining surface texture patterns, applying laser texturing, and applying a new coating to the surface to be treated using the coating applicator (208).