METHOD AND APPARATUS FOR REMOVAL OF MATERIAL UTILIZING NEAR-BLACKBODY RADIATOR MEANS

Abstract: An apparatus and method are disclosed for removal of material from a substrate or structure using a broadband flashlamp-type radiator (200) for providing broadband radiant energy (204), an ultraviolet radiator (302), lamp head or other focusing means (212) for directing the broadband radiant energy (204) and ultraviolet radiant energy (306) onto the surface of the coating or coatings or other material to be removed, thereby resulting in the ablation and photodissociation of the material, and a residual constituents removing means (108), such as flowing CO2 pellets, liquid CO2, jets of compressed air, particles or other flowing gases or liquids.

Description: METHOD AND APPARATUS FOR REMOVAL OF MATERIAL UTILIZING NEAR-BLACKBODY RADIATOR MEANS FIELD OF THE INVENTION The present invention relates to methods and apparatus for paint-stnpping, decoating and other mateπal-removing applications and more particularly to the use of a highly efficient flashlamp or other source of high peak power, high average power, broadband, continuum output radiation for rapidly and efficiently vaponzing the material to be removed, scrubbmg the vaporized matenal and physically displacing the remaining debris BACKGROUND OF THE INVENTION Decoating and paint stripping are specific examples of removing preselected types and amounts of matenals from a substrate or structure Removal of paint from buildings, automobiles, bndges, aircraft and other structures is a very large industry throughout the world Refurbishment of paint on aircraft, for example, is a matter of routine maintenance with an average coat of paint lasting typically between about 3 and about 5 years Furthermore, removal or rust and corrosion of all types, including fouling on the undersides of maritime boats and vessels, is also time-consuming, expensive and difficult Problems associated with decoating or paint removal are vanous In certain instances, recessed or angular areas or areas with otherwise inaccessible surfaces are difficult to treat Mechanical methods of decoating include manual or assisted sanding and scrapmg, grinding with an electric gnnder, and blastmg the surface with particles such as metal or plastic pellets, sand, etc Drawbacks of these methods include the possible damage to underlying substrate structure The upper layer of substrate or structure is often slightly pitted or otherwise damaged and stress hardening is known to occur These changes in substrate or structure integnty or quality can have a negative impact on the function or utility of the structure For example, smooth flat surfaces are aesthetically pleasing on an automobile's painted surfaces The design of an aircraft may be based on a given construction matenal' s physical charactenstics such as static and dynamic strength, shear strength, or modulus of elasticity, and changing these physical charactenstics could have a negative impact on the given material's performance under certain situations Chemical methods of removing coatings or other types of mateπals are similarly fraught with a range of drawbacks The primary requirement is chemical solubility of the material to be removed and essential insolubility of the substrate or structure - a situation often difficult to achieve Particular care must be taken when the substrate or structure is plastic or epoxy-based since these and other organic materials are easily affected by certain solvents Furthermore, chemical processes for decoating, paint-stnppmg and the like often pose a significant risk to human and ammal health and our environment either through direct exposure to employees dunng the process or during waste treatment and down-stream processing, industrial accidents, etc Methods and apparatus for removing matenal. in particular for multi-purpose decoating. stnpping or scaling, based upon delivery of broadband, non-coherent electromagnetic energy such as that produced by a Xenon-gas or other type flashlamp for rapidly and efficiently vaponzing the material to be removed is heretofore unknown Although laser energy has been used to m hundreds of applications to vaponze or ablate all types of mateπals including metals, human tissue and semiconductors, laser devices are dangerous, expensive and often awkward to use U S Patent No 4,867,796 to Asmus et al discusses a method for photo-decontamination of surfaces in which broad band frequency light absorption agents are admixed into the contaminants which are then irradiated As with a laser, as the hght-absorptive agent absorbs the radiation it becomes hot and vaporizes along with the surface decontammant Numerous methods for controlling a flashlamp-type decoating apparatus have been proposed U S Patent No 5,281,798 to Hamm et al proposes a method and system for selectively removing a matenal coating from a substrate or structure usmg a flashlamp in conjunction with a photodetector circuit for sensmg reflected light back from the surface being ablated, thereby providing a feedback signal indicative of the reflected color intensity of the surface being ablated The method is dependent upon a boundary between the coatings or between the coating and the substrate or structure to be distinguished by a visible color change, requires additional optical and processmg means for photodetection and signal processing U S Patent No 5,194,723 to Cates et al proposes another method for controlling a pulsed light matenal removal system based upon detection of "photoacoustic signature signals" generated by the ablation of surface matenal However, the complicated method requires sophisticated robotics and sensitive photoacoustic hardware for calibration which involves initial scanning of a structure along a predetermmed path, detectmg the photoacoustic signature signals, determining an updated scan speed functionally related to the detected photoacoustic signals and controlling the scan speed thereby Furthermore, the method is dependent on the measurement of so-called photoacoustic signature signals which ma> or may not exist or be detectable at the required operating temperatures and for the broad range of matenals for which a flashlamp-type decoating system would be desirable In yet another attempt to overcome the problems associated with using pulsed or continuous wave light energy systems for decoating U S Patent No 5,204,517 also to Cates et al theorizes a method and system for control of a material removal process using "spectral emission discnmmation" This system utilizes, in addition to photoablative light beam radiation from a flashlamp to remove particles from the surface of the substrate or structure, laser light beam radiation which also ablates matenal at the surface of the coated substrate or structure so that such ablating material generates spectral emission which can be detected with additional tuned photo-optics or sensors without interference from the spectral output of the flashlamp In all controls schemes for such flashlamp-type decoatmg systems proposed in the past, complicated optics and sensor equipment including sophisticated and expensive arrays of diodes with required signal processing hardware and software is required Thus, broadly, it is an advantage of the present invention to provide a near-blackbody radiator means for removal of matenal method and apparatus, said near-blackbody radiator means compnsing a highly efficient flashlamp or other type high peak power, high average power, broadband, continuum output radiation for rapidly and efficiently vaponzing the material to be removed It is a further advantage of the present mvention to provide such a method and apparatus which does not contribute to the production of toxic or other chemical waste It is a further advantage of the present invention to provide such a method and apparatus which decontaminates or otherwise reduces the removed matenal to elemental form or other inert, non-reactive, non-toxic, environmentally friendly soot, ash or other form of debns Another drawback of the pnor art is that no control scheme based upon required pulse duration is available for removing paint, other coatings or other matenal from a structure It is an advantage and objective of the present invention to provide a method based on a pulse duration-control scheme for controllably removing predetermined thicknesses of matenal from a structure SUMMARY OF THE INVENTION The present invention is an apparatus for removal of a layer or material coating a substrate or structure utilizing radiant electromagnetic energy, the apparatus including flashlamp-type broadband, near black-body radiator means providing radiant electromagnetic energy in a pulsed mode, the light energy having a predetermined bandwidth which includes infrared and visible electromagnetic radiation, thereby causing photoablation of the layer of material to be removed by formation of vapor/plasma, which includes volatile organic compounds, and further photodissociation of the vaporized material produced thereby, and means for displacing residual constituents of photoablation and photodissociation from the substrate or structure In one embodiment the broadband radiator delivers radiant electromagnetic energy in a pulsed mode at a rate of between about 1 and about 15 pulses per second In one embodiment the broadband radiator delivers radiant electromagnetic energy at a rate of between about 15 and about 50 kW In one embodiment the flashlamp has a gas plasma temperature of between about 9,500°K and about 20,000°K In one embodiment the flashlamp has a gas plasma temperature of between about 9,500°K and about 1 1,500°K In one embodiment the broadband radiator is a high intensity Xenon gas filled flashlamp In one embodiment the broadband radiator and the ultraviolet radiator means are a single, high intensity Xenon gas filled flashlamp In one embodiment the ultraviolet radiator means is a mercury vapor lamp In one embodiment the residual constituent removing means comprises flowing cryogenic matenal. In one embodiment the residual constituent removing means compπses flowing C0 2 pellets In one embodiment the residual constituent removmg means compnses flowing liquid mtrogen In additional embodiments, the residual constituent removing means compnse flowing liquid C0 2 , flowing liquid water, flow g crystalline water particles or snow, flowing compressed air or other compressed gases or liquids A preferred embodiment further compnses a scrubber means for removmg volatile organic compounds from the ablated and photodissociated matenal A preferred embodiment further comprises a filtration means for removing particulate In one embodiment the broadband radiator and the ultraviolet radiator means arc contained within a lamp head assembly, the lamp head assembly directing radiant electromagnetic energy onto the coating matenal to be removed, the lamp head assembly also directing ultraviolet radiation into the vapor/plasma to cause photodissociation of the matenal being removed, the lamp head assembly further comprismg vacuum means for displacing residual constituents of ablated and photodissociated material from the substrate or structure The vacuum means may also serve to capture and contain the flowmg C0 2 pellets, liquid C0 2 or nitrogen, compressed gas, air, liquids or other residual constituent removmg means A preferred embodiment further comprises control means for delivenng radiant electromagnetic energy and ultraviolet radiation according to a predetermmed timing sequence A method for removal of material from a substrate or structure utilizing radiant electromagnetic energy compnses the following steps (A) providing a flashlamp-type near blackbody radiator means to generate radiant electromagnetic energy with a predetermined radiation bandwidth including infrared and visible electromagnetic radiation. (B) delivenng predetermined amounts of both radiant electromagnetic energy and ultraviolet radiation to die at least one layer of matenal to be removed thereby causing ablation and photodissociation of the matenal to be removed, and (C) removmg the residual constituents of ablated and photodissociated matenal from the substrate or structure Another preferred method of the present mvention is based on a pulse duration-control scheme for controllably removing predetermmed thicknesses of matenal from a structure Numerous other advantages and features of the present invention will become readily apparent from the followmg detailed descnption of the mvention and the embodiments thereof, from the claims and from the accompanying drawings BRIEF DESCRIPTION OF THE DRAWINGS FIG 1 A is a radiation profile showing pπor art-radiator means spectral response curves corresponding to two selected plasma temperatures FIG IB is a radiation profile showing near-blackbody radiator means spectral response curves corresponding to three selected plasma temperatures FIG 2 is a representative perspective view of a preferred embodiment of the near- blackbody radiator means decoating system of the present mvention FIG 3 is a representative schematic view of a preferred embodiment of the lamp head assembly of the present mvention FIG 4 is a representative schematic view of a preferred embodiment of the lamp head assembly of the present invention FIGS 5-7 are representative cross section front, top and side views, respectively, of a preferred embodiment of the near black-body radiation means lamp head assembly of the present mvention FIG 8 is a flowchart of a preferred embodiment of the method of the present mvention FIG 9 is a typical timing diagram of a preferred method of decoatmg of the present invention DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Near-Blackbody Radiator Means In one embodiment of the present invention, a near-blackbod} radiator means comprises a high peak power, high average power Xenon-gas filled flashlamp Such a radiator means is capable of delivenng up to 12 MW of peak power with average power up to 50 KW The use of this type of flashlamp for vaponzing solids and thereby decoatmg structures in heretofore unknown Average radiative transfer efficiencies are about 85%, thus most of the radiation is used m the decoating process The power density of the Xenon-gas plasma inside the lamp is such that a strong continuum output is produces Depending on the selected pulse duration and input energy, this continuum output has a peak in the near to far UV region The Xenon-gas plasma temperature, again depending on the selected pulse duration and other factors, can range between about 9,500°K and about 1 1,400 °K, or between about 9,500°K and about 20.000 °K The diameter of the plasma is kept relatively small so that conversion efficiencies, particularl} in the shorter wavelengths, are maximized The term "blackbody" denotes an ideal bodv which would, if it existed, absorb all and reflect none of the radiation falling upon it, its reflectivity would be zero and its absorptivity would be 100% Such a body would, when illuminated, appear perfectly black, and would be invisible except its outline might be revealed by the obscunng of objects beyond The chief interest attached to such a body lies in the character of the radiation emitted by it when heated and the laws which govern the relations of the flux density and the spectral energy distribution of that radiation with varying temperature The total emission of radiant energy from a blackbody radiator takes place at a rate expressed by the Stefan-Boltzmann (fourth power) law, while its spectral energy distnbution is descnbed by Planck's equation, and other empirical laws and formulas Planck's law, often referred to as the fundamental law of quantum theory, expressing the essential concept that energy transfers associates with radiation such as light or x-rays are made up of definite quanta or increments of energy proportional to the frequency of the corresponding radiation This proportionality is usually expressed by the quantum formula E = hυ in which E is the value of the quantum m units of energy and v is the frequency of the radiation The constant of proportionality, h, is the elementary quantum of action, or Planck's constant The relationship is known as Planck's radiation formula, where E-dλ is the intensity of radiation in the wavelength band between λ and (λ + dλ), h is Planck ' s constant, c is the velocity of light, k is the Boltzmann constant and T is the absolute temperature This formula describes the spectral distribution of the radiation from a complete radiator or blackbody This equation can be wntten in other forms, such as in terms of wavenumber instead of wavelength It may also be wntten in terms of wavenumber instead of wavelength intensity The emissivity of the volume emitter (flashlamp plasma) is hard to estimate because of its strong dependence on temperature, wavelength and depth Nonetheless, since the plasma reaches thermodynamic equilibrium very quickly duπng the pulse and the depth, for all practical purposes, and remams nearly constant duπng the penod of equihbπum, the emissivity ε can be desenbed according to wavelength interval Thus, ε > 0 80 [250 n 400 ran], ε = 0 85 [400 ran 750 ran], ε > 0 95 [750 nm ] Hence, the express "near-blackbody radiator" FIG 1 A is a radiation profile showing pπor art-radiator means spectral response curves corresponding to two selected plasma temperatures FIG IB is a radiation profile showing near-blackbody radiator means spectral response curves corresponding to three selected plasma temperatures It will be shown that the plasma temperatures are determined by pulse duration By specifying only the pulse duration, the spectral response and radiative intensities can be controlled Input energy' to the lamp can also be controlled By selectmg appropnate pulse duration and input energy, a selective decoating burst of energy can be attained for virtually any type of coating and substrate or structure The flashlamp-type near-blackbody radiator means of the present invention is designed to handle pulse durations m the range of about 250 μs to about 2000 μs The flashlamp is designed to withstand these pulse durations over a long life and providing pulse to pulse reliability As desenbed herein, generally the type of substrate or structure present will dictate the length of pulse most efficient and efficacious The area bound by the blackbody curves denotes the total blackbody lrradiance as a function of temperature, or R(7) In FIG 1A, the curves represent the following typical pπor art radiator plasma temperatures 7a = 10,026 °K Jb = 9,060 °κ In FIG IB, the curves represent the followmg near-blackbody radiator plasma temperatures for the present invention 7c = 10,456°K Tά = 11,403 °K 7e = 9,589°K A typical range of significant utility is between about 9.500°K and about 1 1,500°K It will be made clear hereby that these temperatures are only representative and that temperatures as high as 20,000 °K and greater are included herein Therefore, in general, to achieve a higher plasma temperature, for a given power rating, the application of shorter pulses of energy will be useful Radiative heat transfers are proportional to differences in temperature to the fourth power, or q « 7 4 - 7 Based on the largest temperature differential between the selected temperatures of a near-blackbody radiator, ΔT = 1814K ° , but the ratio TdJT→ is equal to 1 189, that is 7α is 1 189 times greater than 7"e Thus, total blackbody irradiance, R(7), is (1 189) 4 or about 2 times greater than the irradiance generated at 7e This large increase heat flux from a relatively small increase in plasma temperature is easily attained through predetermmed temporal pulse shaping via the pulse forming network (PFN) circuit of the system The followmg compaπson between typical flashlamp-type decoatmg radiator and the flashlamp-type near-blackbody radiator of the present invention will serve to contrast the overwhelming advantages to using the latter With respect to the flashlamp radiator and operatmg parameters of the prior art, two typical pulse durations, in seconds, will be analyzed t a = 0 001200 s, t b -= 0 001800 s or t a = \200μs, t b = 1800μ s The electron temperature T e of the resulting gas plasma inside the lamp is a function of the input energy E 0 , the inside surface area of the lamp A and pulse duration t→ and is given by the formula oAt„ where σ is the Stefan-Boltzman constant equivalent to 5 67 x 10 u watt/cm K 4 Thus, utihzmg a lamp with an inside diameter of 5 mm and an input energy of 1,800 joules, it can be shown that 7a f = 10.026°K and , = 9,060°K In comparison, utilizing a flashlamp-type near-blackbody radiator of the present invention having a slightly larger mside diameter of 10 mm, an input energy of 3,750 joules and selecting much shorter pulse durations such as t c = 339 s, t d = 480μs. and t„ = 679μs, it can be shown that 7c, = 11,403 β K. Tά, = 10,456°K, and 7e e = 9,589°K Total blackbody irradiance, a function of the pulse duration and the electron plasma temperature, is given by the formula Rt (Tx )=σTx * The followmg irradiances are typical of the pπor art flashlamp radiator R/ a (7a c ) = 57,296 watt/cm 2 , R b (7b c ) = 38,197 watt/cm 2 The following irradiances are possible using the flashlamp-type near-blackbody radiator of the present invention R C (7c e ) = 95,856 watt/cm 2 , R d (7α e ) = 67,781 watt/cm 2 , and R e (7e e ) = 47,928 watt/cm 2 Thus, much higher total irradiances, I e , the radiation from the emitter due solely to excitation of the plasma-gas particles, by using shorter pulse durations and higher input energy can now be achieved Furthermore, the total power density of the lamp, I e , the total power emitted by the lamp, including radiation from the emitter as well as thermal energy, will be given by the formula Solvmg for radiators of the pnor art, a p = 63,662 watt cm 2 , Pb p = 42,441 watt/cm 2 , and solvmg for near-blackbody radiators of the present mvention, c p = 106,507 watt/cm 2 , d p = 75,312 watt cm 2 , and Λ p = 53,253 watt/cm 2 Decoating Apparatus FIG 2 is a representative perspective view of a preferred embodiment of the near- blackbody radiator means decoating system of the present invention The decoatmg system 100 is powered by power supply 102 The power supply comprises an approximately 15 to 50 kilowatt charging supply , pulse forming network means, controller means, and electronics cooling system, all contained within a cabinet A power cable 104 leads to distribution box 106. A source of residual constituents removal means 108 is connected to distribution box 106 via hose 110 It will be understood that such residual constituent removal means 108 includes, but is not limited to, flowing pelletized or liquid CO flowing liquid water, flowmg crystalline water particles or snow, flowmg compressed nitrogen, air or other compressed gases or liquids Additionally, other particles including plastic pellets, sand, or other conventionally used particles may be u sed Vacuum source/HEPA filter and VOC scrubber means 112 is connected to distnbution box 106 with vacuum hose 114 An integrated, central umbilical cable 116 leads from distribution box 106 to mounted or hand-held lamp head assembly 118 The decoating system is designed to be hand held However, it will be understood that the present invention may be adapted to applications and mounted to a moving member or fixed and stationary relative to a movmg surface being decoated For tall structures such as oil tanks, aircraft, tall walls or supports, etc , where the weight of the umbilical creases with height, a block and tackle pulley system can be mstalled to counter-balance it ' s weight Lack of adequate hangar gantry, bndge support or other can be overcome by erect g a free-standing support FIG 3 is a representative schematic view of a preferred embodiment of the lamp head assembly 118 of the present invention Near-blackbody radiator means 200 such as an adapted flashlamp is the source of noncoherent, broadband light used to vaporize the coatmg matenal bemg removed The radiator means is controlled by flashlamp driver 202 The radiator means produces radiation beams 204 which are directed onto the surface of the coatmg bemg removed A preferred embodiment of the radiator means compnses a flashlamp with a nitrogen port 206 m the lamp cavity supplied with a source of nitrogen 208 A quartz plate 210 and reflector 212 separate the radiator means from the structure bemg decoated As the top coatmg is vaporized, jets 214 blast the residual constituents removal means mateπals 108, such as compressed air, gases, liquids, etc onto the work surface as well as onto the quart plate in the directions shown by arrows A to remove the layer of fine ash produced by the device A light buffing wheel 216 removes any remaining ash or soot or other debris created by the vapoπzed removed material which all eventually is sucked up m the direction shown by arrow B and removed completely through vacuum nozzle 218 which is supplied by vacuum source 112 Thus, the coating of material to be removed 220 is vaponzed as the device is translated over the surface of the coatmg to be removed m the direction shown by arrow C leaving behind zero, one or more intermediate layers 222 which coat substrate or structure 224 It will be understood that the device can be used to dccoat substrate or structures having one or more layers of coating matenal, one of more of these coatmg layers to be removed by the process, as desired FIG 4 is a representative schematic view of a preferred embodiment of the lamp head assembly 300 of the present invention To further enhance the decoating method of the present invention, a plurality of linear mercury vapor ultraviolet (UV) lamps 302 are placed at the bottom of the mam reflector cavity 304 so as to irradiate the vapor/plasma plume with UV radiation 306 continuously As will be discussed below, this adaptation will aid in the photochemical destruction of the large organic molecule vapors, plasma or particulate disrupted by the major high energy flux of flashlamp type or other broadband radiator 200 An adapted quart plate 308 or other protective system is useful The hand-held lamp head assembly has one or more handles In one embodiment, the lamp head assembly has two ergonomically designed handles, each with a lamp firing tngger Two tπggers are used to msure that the system cannot fire accidentally if one tngger should be accidentally depressed On one or more handles or elsewhere on the assembly is a set of thumb or otherwise activated controls A preferred embodiment compnses a small annunciator panel located in the center of the lamp head assembly at an ergonomically chosen location so that the operator can easily survey the instantaneous operating parameters of the system The followmg control can be provided by a number of different means, as desenbed above, including thumb switches 1 Power settings Typically, 15 pps (Pulses per second) at 50 KW average power (time limited) can be selected A default setting of 4 pps at 15 KW average power, rated for contmuous duty 2 Residual constituent matenal removal means flow - mterlock overnde control This switch, while depressed or otherwise activated, initiates flow of C0 2 pellets, compressed gases, liquids or other residual constituent matenals removal means regardless of the interlock state 3 Vacuum control - ON/OFF With a default setting Off, the control is provided for convenience Typically, once the vacuum is turned OFF, then the flashlamp and constituent matenal removal means flow is disabled In use lamp shutters for the mercury UV lamps are closed 4 Mercury UV lamp ON/OFF Default setting is ON 5 Mercury UV lamp shutter OPEN/CLOSED This control is used to overnde the typically three minute lamp warm up penod on the lamp start is avoided Default setting is CLOSED 6 Lamp head assembly dwell - interlock override This feature enable the lamp head assembly to dwell over a certain surface area, while fully activated, when depressed or otherwise manually asserted The front of a preferred embodiment of the lamp head assembly has the vacuum nozzle and debns brush mounted directly to it In this configuration the lamp head assembly is designed to be drawn towards the operator rather than away The C0 2 pellets, compressed gases, liquids or other residual constituent matenals removal means 108 are directed at an angle towards the quartz plates while other nozzles are directed at the substrate or structure The C0 2 pellets, compressed gases, liquids or other residual constituent materials removal means 108 are applied in a senes of pulses in-between the flashlamp pulses This is to allow all wavelengths to reach the work surface with minimum attenuation There is also a protective skirt suπounding the lamp head assembly, near the lower portion, to help create a negative pressure region via the vacuum system, to contain or otherwise capture toxic mateπals generated by the ablative process It is important to note that the angle at which the quartz plates are placed relative to the incident light from the near flashlamp-type black-body radiation means must be considered in light of the wavelengths of light being generated and the mdex of refractivity of the plate itself Furthermore, while the C0 2 pellets, compressed gases, liquids or other residual constituent matenals removal means 108 would otherwise pose no significant attenuation of the short UV wavelengths, they must be directed at the quartz plate m a predetermmed angle in order to prevent the build up of soot or other debns which would itself cause significant attenuation of all wavelengths generated m the process FIGS 5-7 are representative cross section front, top and side views, respectively, of a preferred embodiment of the near black-body radiation means lamp head assembly 400 of the present mvention As shown, the lamp tube 402 of the assembly sits mside the reflector cavity 404 The lamp tube 402 is disposed within flow tube 406 Cooling water is circulated through the flow tube, entering the assembly through put ports 408 and exiting through output port 410. Anode lead 412 and cathode lead 414 extend from either end of the lamp tube and are directed around the assembly to the rear 416 of the assembly to avoid interference with operations at the front 418 of the assembly during operation Lamp tngger 420 can be placed as shown or elsewhere Nitrogen gas is pumped mto the reflector cavity 404 through input port 422 and is allowed to escape through output port 424 Safety interlocks are provides to ensure that the vacuum and scrubber system is activated if the flashlamp and/or mercury vapor UV lamps are runmng so that dangerous levels of ozone or other contaminants do \not build up in the work area .An mterlock is provided to ensure that there are no ground faults present in the lamp head assembly or anywhere else Also, there is a monitormg system to reduce the applied energy or to stop the flashlamp entirely if the dwell time on a particular spot exceeds some preset reference value This system will protect the substrate or structure from overheat g. from cold stress or mechanical damage from excessive bombardment by C0 2 pellets, compressed gases, liquids or other residual constituent materials removal means 108 In one embodiment, the system measures the movement of the lamp head assembly from sensors in the tracks that the lamp head assembly glides on Preferred Methodology FIG 8 is a flowchart of a preferred embodiment of the method of the present mvention Duπng the first step, sub-system parameters are input into the control means and the various sub-systems are initialized These individual sub-systems include the lamp dπvers, the C0 2 pellets, compressed gases, liquids or other residual constituent mateπals removal means 108 delivery system, the vacuum system, the VOC scrubber and dissociation system, ground fault interlocks and other system interlocks, as desenbed above and as will be expanded by those skilled in the art Subsequent to initialization, the system is ready for operation Control means ensure that both fiπng buttons are depressed manually and simultaneously to ensure intentional operation Failure to depress both fiπng buttons will allow the system to remain idle in a state according to default parameters Once both buttons are depressed simultaneously, the residual constituent vacuum and effluent gas scrubber and filtration systems are enabled If so equipped, the UV lamp shutters are opened Thereafter, the near black-body radiator flashlamp will fire at the selected power at a preset, predetermmed pulse rate for a predetermmed amount of time Following the fiπng of the flashlamp, the subsystem controlling the C0 2 pellets, compressed gases, liquids or other residual constituent mateπals removal means will be enabled After allowing the lamp head assembly to dwell in a certain position for a predetermmed reference limit amount of time, a timing circuit disables the power supply to the flashlamp In one mode, the timing circuit disables the flashlamp dπvers after a preset reference limit In another mode, the timing circuit ensure contmuous motion at a predetermmed rate, thus controlling the power flux rate After the flashlamp dπvers are disabled, the C0 2 pellets, compressed gases, liquids or other residual constituent matenals removal means is also disabled A second timing circuit determines whether the lamp head has moved sufficiently to satisfy a minimum dwell threshold If not, the flashlamp and C0 2 pellets, compressed gases, liquids or other residual constituent mateπals removal means systems arc maintained m a disabled sate If so, the flashlamp and matenal removal systems are enabled agam and the first timing circuit is activated to determine lamp head dwelling in the position for the preset reference limit Phase I: Initial Vaporization and Ablation In Phase I of a prefeπed method of the present invention, the radiator means delivers a pulse having a predetermmed duration, power rating and frequency spectrum A thin layer of the coating material or other matenal to be removed is vaporized or ablated by the radiation This thin layer is typically on the order of between about 3 and about 4 mils (thousandths of an inch) Radiant energy in the approximately 400 nm to approximately 10 μm wavelength range is used to vapoπze the upper layer of material to be removed, and is therefore referred to as the vaporization bandwidth (VBW) energy A resultant vapor/plasma intermediate is produced In many cases this resultant intermediate will be opaque to VBW energy In such cases, further irradiation with VBW energy, as with subsequent pulses, will lead to an increase in the temperature of the vapor/plasma Care must be taken so as not to increase the temperature of this vapor/plasma excessively such that thermal energy in the form of heat is transfened to the substrate or structure or lower, non-removed layers As stated previously, the vapoπzation process is different for different coatings and substrate or structures However, temporal manipulations and in some cases manipulation of the mput energy levels mto the radiator means or flashlamp are usually all that need to be made to effectively remove the particular coating from the particular substrate or structure Typical compounds or coatmgs which can be effectively ablated using the methods and apparatus of the present invention include polyurethane based paints, and polyamide or other type epoxy based pnmers, protective coatmgs, etc Typical substrate or structures mclude wood, low or high carbon steel, virtually all typical or specialized types of metal, cement and concrete, carbon and durametalhc composites and fiberglass or other non-carbon fiber and epoxy based composite substrate or structures Greater success is achieved when the substrate or structure has a relatively high thermal conductivity compared with that of a coating to be removed With a substrate or structure with a low thermal conductivity, as m a non-carbon fiber epoxy based composite, irreparable thermal damage can be done if too much VBW energy is delivered to the vapor/plasma layer Mateπals with a relatively higher thermal conductivity will withstand greater thermal energy transfer and will dissipate the heat through the material more easily, which heat would otherwise build up at the surface of the substrate or structure FIG 9 is a typical timing diagram of a preferred method of decoating of the present invention Representatively, Tl is the pulse duration of the flashlamp Typically, this pulse ranges from between about 300 μsec to about 600 μsec, depending on the surface to be decoated T2 represents the relative time that the C0 pellets, compressed gases, liquids or other residual constituent mateπals removal means are applied to the surface As is apparent by the drawing, initiation of delivery of such removal means is delayed until just after or simultaneous with the termination of a lamp pulse Delivery of C0 2 pellets, compressed gases, liquids or other residual constituent materials removal means is sustained until just before the start of the next flashlamp pulse The interval T3 must be long enough to allow the vacuum system to evacuate the C0 2 pellets, compressed gases, liquids or other residual constituent matenals removal means from the surface to be ablated T3 is typically between about 10 milliseconds and about 200 milliseconds Finally, the pulse repetition or cyclmg rate T4 ranges from about 4 to about 15 pulses per second, or about 250 to about 66 milliseconds per pulse This timing protocol can be achieved utilizing microprocessor based programmable or preprogrammed controllers and associated hardware for actuating the flashlamp drivers, removal means system drivers, etc , and will be known to those skilled in the art Phase II: VOC Scrubbing In Phase II of a prefeπed embodiment of the present mvention, further if not complete combustion of the volatile organic compounds (VOCs) is achieved by bombardment of the vapor/plasma layer with ultra-violet (UV) portions of lnadiation spectrum These portions are referred to as the scrubber bandwidth (SBW) which covers a range of between about 180 and about 390 nm During pulsmg of the near-blackbody radiator means, m particular those pulses subsequent to initial Phase I vaponzation and ablation, the vapor/plasma layer which is otherwise partially opaque to VBW energy will be exposed to a high energy flux of UV light This vapor/plasma layer is at least partially transparent to UV light which will cause photodissociation of any organic compounds, mcludmg VOCs Furthermore, catalytic action on suspended metals such as Ti, Pb, Cr and their vanous oxides, etc will aid m the complete combustion of these compounds .An increase in the thermal energy based upon absorption of infrared and other frequency light will elevate the fraction of those organics with energies in excess of the activation energy necessary to ionize or dissociate organic molecules This increase in temperature coupled with heterogeneous catalytic action of the suspended metalhcs which will actually help to lower the required activation energies of those organic species provides a very efficient and complete scrubbing of the vaporized material which has been removed from the substrate or structure Furthermore, rapid combustion accomplished via essentially instantaneous vaporization followed by scrubbing will help to dissipate any excess heat generated and will avoid dumping that excess radiant energy into the vapor/plasma layer, reducing the chance of overheatmg the substrate or structure In prefeπed embodiments, an auxiliary UV radiation means w ill simplify an otherwise more complicated radiation pulse/dissociation cycle protocol To further enhance the Phase II ablation process, one or more linear mercury vapor UV lamps are placed at the bottom of the mam reflector cavity so as to irradiate the vapor/plasma plume continuously This adaptation aids m the photochemical destruction of the large organic compounds liberated dunng the ablative process The UV lamps are designed to produce discrete atomic line UV radiation The pnnciple bandwidth ranges from between about 150 nm to about 500 nm, which enhances the photodissociation of organic molecules released by ablation One mechanism of this photodissociation is based on catalytic reaction with the metallic substrate or structure, e.g solid-phase aluminum, or with suspended metallic and metallic oxide particulatc containing coating matenals when present These lamps also produce a great amount of ozone gas This gas production also aids in oxidation and other forms of degradation of organic molecules Phase III: Removal and Trapping Followmg Phase I and Phase II, a layer which comprises a fine ash, soot or other essentially inert, inorganic and/or metallic debris is formed This fine ash or other form of residual constituents must be removed from the work surface as well as from the outer surface of the quartz plate This is achieved by blasting both surfaces with C0 2 pellets, compressed gases, liquids or other residual constituent mateπals removal means Individually oriented jets blast the quartz plate and the work surface and a buffing wheel followmg the blasting will effectively remove all significant amounts of this ash or other debns The debns can conveniently be displaced through capture by a vacuum system, the vacuum nozzle placed at the rear of the apparatus The debris or other effluents can then easily be sent through a stra er, filter, micro-filtration system and/or through an activated carbon scrubbing matrix, to trap the waste for disposal or reclamation Furthermore, the vacuum system in combination with the phase transition of the liquid or solid C0 2 or other matenal from solid to gas will safely remove the ozone gas from the work area As is well known, UV lamps are efficient ozone producers Ozone, along with any contaminants and the other constituents of the ablated vapor/plasma plume, is then scrubbed by catalytic or other chemical methods m the high efficiency particulate arresting (HEPA) filter/vacuum system To ensure that no dangerous ozone is produced or released around personnel operating the equipment, the vacuum/plasma fume scrubber is interlocked with the lamp drivers This interlock system will prevent fiπng of the flashlamp circuit without adequate vacuum operation and can be tied to electronics of the two systems, auxiliary sensors to monitor vacuum operation, or manually or otherwise Pulse Duration-Control Therefore, if the coπect operating parameters of the flashlamp are selected, pulse duration can be used for independent control of the device A thin layer of unionized gas on the order of a few molecules thick exists between the un-affected structure and the "floor" of the hot gas/plasma layer (q v , vapor layer) This layer acts as an insulator on the surface of the structure, and the surface is actually somewhat "cooled" Additional cooling may be used, but in prefeπed methods of the present invention, residual material is removed without heat generation in the structure itself Additional complications due to excessive cryogenic cooling of the structure can be avoided by interlocking cooling and radiant power agamst excessive dwell tune The novelty of the approach of the present mvention is based upon the use of pulse duration as the mdependent control of ablation depth The depth of ablation and hence its heat penetration mto the coatmg vanes directly with the pulse duration and thermal conductivity of the coatmg matenal and other structural components, and mversely with the heat capacity and density of the coatmgs, substrates and other matenals mvolved Thus, independently controllmg pulse duration, given a set of parameters including power and energy, etc , can be used to control ablation depth Unless defined otherwise, all technical and scientific terms used herem have the same meaning as commonly understood by one of ordinary skill in the art to which this mvention belongs Although any methods and materials similar or equivalent to those desenbed can be used in the practice or testing of the present invention, the prefeπed methods and mateπals are now desenbed All publications and patent documents referenced in this application are incorporated herein by reference While the principles of the invention have been made clear in illustrative embodiments, there will be immediately obvious to those skilled in the art many modifications of structure, arrangement, proportions, the elements, materials, and components used in the practice of the invention, and otherwise, which are particularly adapted to specific environments and operative requirements without departing from those principles The appended claims are intended to cover and embrace any and all such modifications, with the limits only of the true purview, spiπt and scope of the invention

Claims: We claim 1 .An apparatus for removal of a layer of material coatmg a substrate utihzmg radiant electromagnetic energy, the apparatus compnsing near black-body radiator means for providing radiant electromagnetic energy m a pulsed mode, the radiant electromagnetic energy having a bandwidth which includes wavelengths between about 390 nm and about 1 100 nm, ultraviolet radiator means for providing electromagnetic radiation having a bandwidth which mcludes wavelengths between about 150 nm and about 390 nm, means for directing the electromagnetic radiant energy onto the layer of matenal coating the substrate for photoablation and photodissociation of the material by formation of a matenal vapor/plasma, and means for displacing residual constituents of photoablation and photodissociation from the substrate 2 The apparatus of Claim 1 further comprismg a means for provid g radiant electromagnetic energy in a pulsed mode 3 The apparatus of Claim 1 wherein the near black-body radiator means delivers radiant electromagnetic energy in a pulsed mode at a rate of between about 1 and about 15 pulses per second 4 The apparatus of Claim 1 wherein the near black-body radiator means delivers radiant electromagnetic energy at a rate of between about 15 and about 50 Kw 5 The apparatus of Claim 1 wherem the near black-body radiator means and the ultraviolet radiator means are at least one gas filled flashlamp havmg a gas plasma temperature of between about 9,500°K and about 20,000°K 6 The apparatus of Claim 1 wherein the near black-body radiator means and the ultraviolet radiator means are at least one gas filled flashlamp havmg a gas plasma temperature of between about 9,500°K and about 11,500°K 7 The apparatus of Claim 1 wherein the near black-body radiator means is a high intensity Xenon gas filled flashlamp 8 The apparatus of Claim 1 wherein both the near black-body radiator means and the ultraviolet radiator means are a single, high mtensity Xenon gas filled flashlamp 9 The apparatus of Claim 1 wherem the ultraviolet radiator means is a mercury vapor lamp 10 The apparatus of Claim 1 wherein the residual constituents removing means compnses flowing cryogenic material 11 The apparatus of Claim 1 wherem the residual constituents removmg means compnses flowmg C0 2 pellets 12 The apparatus of Claim 1 wherem the residual constituents removing means compnses flowmg liquid nitrogen 13 The apparatus of Claim 1 further comprismg a scrubber means for removmg volatile organic compounds from the photoablated and photodissociated matenal 14 The apparatus of Claim 1 further comprising a filtration means for removmg particulate 15 The apparatus of Claim 1 wherem the near black-body radiator means and the ultraviolet radiator means are contained within a lamp head assembly, the lamp head assembly directing radiant electromagnetic energy onto the coatmg matenal to be removed, the lamp head assembly also directing ultraviolet radiation mto die matenal vapor/plasma to cause photodissociation of the material bemg removed, the lamp head assembly further compnsing vacuum means for displacing residual constituents of photoablated and photodissociated material from the substrate 16 The apparatus of Claim 15 further compnsing control means for delivenng radiant electromagnetic energy and ultraviolet radiation accordmg to a predetermmed timing sequence /// 17 A method for removal of a layer of matenal coating a substrate utilizing radiant electromagnetic energy, the method compnsing the following steps providmg a flashlamp-type near blackbody radiator means to generate radiant electromagnetic energy with a bandwidth mcluding wavelengths between about 150 nm and about 1 100 nm, delivenng a predetermmed amount of radiant electromagnetic energy with a bandwidth including wavelengths between about 390 nm and about 1 100 nm to the layer of matenal, delivenng a predetermined amount of radiant electromagnetic energy with a bandwidth including wavelengths between about 150 nm and about 390 nm to the layer of material, thereby causing photoablation and photodissociation of the material to be removed, and removing the residual constituents of photoablated and photodissociated material from the substrate 18 .An apparatus for removing matenal from a structure compnsing a broadband radiator for generating radiant energy with wavelengths between about 390 nm and about 1 100 nm, an ultraviolet radiator for generating radiant energy with wavelengths between about 150 nm and about 390 nm, means for directing the radiant energy onto the matenal for ablation and photodissociation of the matenal by formation of a matenal vapor/plasma, and means for displacing residual constituents of ablation and photodissociation from the structure 19 The apparatus of Claim 18 in which at least a portion of the radiant energy is generated m a pulsed mode 20 The apparatus of Claim 19 m which the pulsed portion of radiant energy is generated at a rate of between about 1 and about 15 pulses per second 21 The apparatus of Claim 18 wherem the broadband radiator generates radiant energy at a rate of between about 15 and about 50 KW. /// 22 The apparatus of Claim 18 wherein the radiant energy is produced by at least one gas filled flashlamp having a gas plasma temperature of between about 9,500 °K and about 20,000°K 23 The apparatus of Claim 18 wherein the radiant energy is produced by at least one gas filled flashlamp having a gas plasma temperature of between about 9.500°K and about 11,500°K 24 The apparatus of Claim 18 wherem the broadband radiator is a high intensity Xenon gas filled flashlamp 25 The apparatus of Claim 18 wherein both the broadband radiator and the ultraviolet radiator are a single, high mtensity Xenon gas filled flashlamp 26 The apparatus of Claim 18 wherein the ultraviolet radiator is a mercury vapor lamp 27 The apparatus of Claim 18 wherem the residual constituents removing means compnses a flowmg cryogenic matenal 28 The apparatus of Claim 18 wherem the residual constituents removmg means comprises flowmg C0 2 pellets 29 The apparatus of Claim 18 wherein the residual constituents removing means comprises flowmg C0 liquid 30 The apparatus of Claim 18 wherein the residual constituents removmg means compnses flowing liquid nitrogen 31 The apparatus of Claim 18 wherem the residual constituents removmg means compnses flowing compressed gas 32 The apparatus of Claim 18 wherem the residual constituents removmg means comprises flowmg compressed air 33 The apparatus of Claim 18 wherein the residual constituents removmg means compnses j ets of compressed air 34 The apparatus of Claim 18 wherem the residual constituents removing means compnses a flowing liquid 35 The apparatus of Claim 18 wherein the residual constituents removing means comprises flowing particles 36 The apparatus of Claim 18 further compnsing a scrubber means for removmg volatile organic compounds from the ablated and photodissociated matenal 37 The apparatus of Claim 18 further compnsing a filtration means for removmg particulate 38 The apparatus of Claim 18 wherein the broadband radiator and the ultraviolet radiator means are contained within a lamp head assembly, the lamp head assembly directmg the radiant energy onto the matenal bemg removed, the lamp head assembly also directing ultraviolet radiant energy into the material vapor/plasma to cause photodissociation of the matenal bemg removed 39 The apparatus of Claim 18 further compnsing vacuum means for displacing residual constituents of ablated and photodissociated matenal from the structure 40 The apparatus of Claim 18 further compnsing control means for delivenng broadband radiant energy and ultraviolet radiant energy accordmg to a predetermmed tinung sequence /// 41 A method for removal of matenal from a structure using radiant energy, the method compnsing the followmg steps providing broadband radiant energy from a flashlamp-type radiator with a bandwidth between about 150 nm and about 1100 nm, delivenng a predetermined amount of broadband radiant energy with a bandwidth between about 390 nm and about 1 100 nm to the matenal, delivenng a predetermined amount of ultraviolet radiant energy with a bandwidth between about 150 nm and about 390 nm to the material, thereby causing ablation and photodissociation of the matenal to be removed, and removing the residual constituents of ablated and photodissociated material from the structure 42 The method of Claim 41 in which at least a portion of the radiant energy is delivered to the material m a pulsed manner 43 The method of Claim 41 in which removal of the residual constituents of ablation and photodissociation is achieved using flowing cryogenic matenal 44 The method of Claim 41 m which removal of the residual constituents of ablation and photodissociation is achieved using flowmg C0 2 pellets 45 The method of Claim 41 in which removal of the residual constituents of ablation and photodissociation is achieved usmg jets of compressed air 46 The method of Claim 41 m which removal of the residual constituents of ablation and photodissociation is achieved usmg flowmg liquid 47 The method of Claim 41 in which removal of the residual constituents of ablation and photodissociation is achieved using flowmg gas 48 The method of Claim 41 in which removal of the residual constituents of ablation and photodissociation is achieved using flowmg solid particles /// 49 The method of Claim 41 further including the step of coolmg at least a portion of the structure pπor to delivenng radiant energy to the matenal 50 The method of Claim 41 further including the step of cooling at least a portion of the structure subsequent to delivenng radiant energy to the matenal 51 The method of Claim 41 further including the step of coolmg at least a portion of the structure contemporaneously with delivenng radiant energy to the matenal 52 A method for controlling removal of material from the surface of a structure with radiant energy comprising the following steps, in combinatiαfeternuning thermal conductivities, densities and heat capacities of the matenal to be removed, determining a pulse duration of broadband radiant energy, with a bandwidth between about 390 nm and about 1100 nm, required for removal of the desired thickness of matenal by direct coπelation of the pulse duration and thermal conductivity and inverse coπelation with the heat capacities and densities of the material, and determining a pulse duration of ultraviolet radiant energy, with a bandwidth between about 150 nm and about 390 nm, required for removal of the desired thickness of material by direct coπelation of the pulse duration and thermal conductivity and inverse correlation with the heat capacities and densities of the matenal /// 53 A method for removal of a desired thickness of material from the surface of a structure with radiant energy comprising the following steps, in combmation determining thermal conductivities, densities and heat capacities of the matenal to be removed, determining a pulse duration of broadband radiant energy required for removal of the desired thickness of matenal by direct coπelation of the pulse duration and thermal conductivity and inverse coπelation with the heat capacities and densities of the material, determining a pulse duration of ultraviolet radiant energy required for removal of the desired thickness of matenal by direct coπelation of the pulse duration and thermal conductivity and inverse coπelation with the heat capacities and densities of the matenal, providing at least one pulse of broadband radiant energy with a bandwidth between about 390 nm and about 1100 nm to the matenal to be removed havmg the determined pulse duration, providing at least one pulse of ultraviolet radiant energy with a bandwidth between about 150 nm and about 390 nm to the matenal to be removed having the determmed pulse duration, thereby causmg ablation and photodissociation of the matenal to be removed, and removing any residual constituents of ablated and photodissociated matenal from the structure ///

Inventors: BENDER JIM, BENDER, JIM
Applicants: NEW STAR LASERS INC, NEW STAR LASERS, INC.
Application year: 1997
Main classification: B08B7
IPC codes: B08B7, B44D3, C02F1