Note: Descriptions are shown in the official language in which they were submitted.
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
CUTTING MACHINERY LASER SYSTEM
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of US Provisional Application No.
62/568,654 filed on October 5, 2017 entitled Cutting Machinery Laser System
incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] The present application relates generally to the field of cutting a
sheet or roll
with a blade and cutting a sheet with a laser.
SUMMARY
[0003] In one embodiment a cutting apparatus comprises a cutting table and a
laser belt
movably supported about the cutting table about a first roller and a second
roller. A
horizontal rail extends across the cutting table. A laser assembly includes a
first
portion having a laser tube operatively secured to the horizontal rail and a
second
portion operatively secured to the first portion, the second portion including
a laser
beam bender assembly.
[0004] In one embodiment a cutting apparatus comprises a cutting table and a
laser belt
movably supported about the cutting table about a first roller and a second
roller, the
laser belt movable along a direction of travel extending perpendicular to the
first roller
and the second roller. A horizontal rail extends across the cutting table
substantially
between and parallel to a longitudinal axis of the first roller and second
roller. A laser
assembly includes a first portion having a laser tube operatively secured to
the
horizontal rail and a second portion operatively secured to the first portion,
the second
portion including a laser beam bender assembly. The first portion of the laser
assembly
includes a housing having a longitudinal axis parallel to the direction of
travel of the
laser belt
[0005] In one embodiment a cutting apparatus comprises a cutting table and a
laser belt
movably supported about the cutting table about a first roller and a second
roller, the
laser belt movable along a direction of travel extending perpendicular to the
first roller
1
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
and the second roller. A horizontal rail extends across the cutting table
substantially
between and parallel to a longitudinal axis of the first roller and second
roller. A laser
assembly includes a first portion having a laser tube operatively secured to
the
horizontal rail and a second portion operatively secured to the first portion,
the second
portion including a laser beam bender assembly. The bracket is movable along
the
horizontal rail. The bracket being removable from the horizontal rail while
coupled to
the at least the first portion of the laser assembly.
[0006] In one embodiment a cutting system includes a cutting table and a first
cutting
material belt movably supported about the cutting table. A second cutting
material is
removably supported above the first cutting material. The laser cutting
material
includes a metal material having a plurality of apertures extending
therethrough.
[0007] In one embodiment a cutting system includes a cutting table and a laser
cutting
material formed of a metal material having a plurality of apertures extending
therein.
[0008] In one embodiment a laser cutting material includes a metal material
operatively
adhered to a carrier material, the metal material having a plurality of
apertures formed
therein and a plurality of disks being located directly below a respective
aperture.
[0009] A process for forming a laser cutting material comprising securing an
aluminum
foil to a carrier material and creating apertures into the aluminum foil.
[0010] In one embodiment a cutting material includes a plurality of panels
with each
panel including a base layer and an aluminum layer secured to the base layer.
Each
panel being secured to an adjacent panel with a connector.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] This application will become more fully understood from the following
detailed
description, taken in conjunction with the accompanying figures, wherein like
reference
numerals refer to like elements in which:
[0012] FIG. 1 is a top isometric view of a cutting system with a surface
loader.
[0013] FIG. 2 is a top isometric view of the cutting system of FIG. 1 with the
surface
loader in a second engaged position.
[0014] FIG. 3 is a top isometric view of the cutting system of FIG 1 with the
surface
layer loaded onto the table.
[0015] FIG. 4 is a front view of the cutting system of FIG. 3.
2
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
[0016] FIG. 5 is a view of a portion of the surface of FIG. 3.
[0017] FIG. 6 is close up view of FIG. 3 generally taken along area 6-6.
[0018] FIG. 7 is a cross-sectional view taken generally along lines 7-7 of
FIG. 6.
[0019] FIG. 8 is cross-sectional view taken generally along lines 8-8 of FIG.
6.
[0020] FIG. 9 is cross-sectional view taken generally along lines 9-9 of FIG.
8.
[0021] FIG. 10 is an isometric view of a surface material.
[0022] FIG 11 is an isometric partial view of the surface material of with
SCORES
extending across the surface material.
[0023] FIG. 12 is a cross sectional view of the surface material taken
generally along
lines 12-12 of FIG. 10.
[0024] FIG 13A is a surface material loading station in one embodiment.
[0025] FIG. 13B is a surface material loading station in a second embodiment.
[0026] FIG. 14 is a top isometric view of a cutting system with the surface
material
positioned on the conveyor material with a graphic material positioned on the
surface
material.
[0027] FIG 15 is a top isometric view of a cutting system with a laser cutting
belt on
top of a first cutting belt.
[0028] FIG. 16 is a partial cutaway view of the laser cutting belt and first
cutting belt.
[0029] FIG. 17 is a cross sectional view of the laser cutting belt and first
cutting belt
taken generally along lines 17-17 of FIG. 16.
[0030] FIG. 18A is an exploded view of the laser cutting belt prior to
assembly
[0031] FIG. 18B is a side view of the laser cutting belt layers prior to the
application of
heat and pressure.
[0032] FIG. 18C is a side view of the laser cutting belt after the application
of heat and
pressure.
[0033] FIG. 18D is a side view of the laser cutting belt after holes are
punched
therethrough.
[0034] FIG. 19 is a schematic view of the laser cutting belt being bent at an
angle
having a radius.
[0035] FIG 20 is an embodiment of a cutting system.
[0036] FIG 21 is a close up of the cutting head of the system of FIG 20.
[0037] FIG 22 is a close up of the laser bracket of FIG 21.
3
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
[0038] FIG 23 is an isometric view of the laser beam bender assembly of FIG
21.
[0039] FIG 24 is an isometric view of the laser expander of FIG 21.
[0040] FIG 25 is a close up of the tensioner system of the dual idler roller
system of
FIG. 20.
[0041] FIG. 26 is a view of the laser tube.
[0042] FIG 27 is an exploded view of the laser beam bender assembly.
[0043] FIG. 28 is the laser lens holder and expansion assembly.
[0044] FIG. 29 is a cross sectional exploded view of a laser cutting belt.
[0045] FIG. 30 is a cross sectional exploded view of a laser cutting belt.
[0046] FIG. 31 is a cross sectional exploded view of a laser cutting belt.
[0047] FIG 32 is a view of a zipper connector for the laser belt.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0048] Referring to FIG. 1 a cutting system 110 includes a cutting table 112
and a
cutting surface transfer station 114. Cutting table 112 includes a first
cutting material
116 and a first conveyor system 118. Cutting table 112 further includes a
cutter system
120 including a pair of side rails 122, 124 and a horizontal rail 126
supporting a cutter
128. Cutter 128 includes a cutting head 130 that may include one cutting tools
such as
a blade, a router, or other similar cutting tools known in the art. Cutting
head 130 may
also include a sensor 132 such as an optical detector including but not
limited to a CCD
camera known in the art to assist in locating a sheet 134 to be cut. In one
embodiment a
vacuum system is provided to draw air through the top surface of the first
cutting
material 116 into the table to assist in maintaining a sheet 134 positioned
relative to a
portion of the surface of the first cutting material 116. Where sheet 134 is a
sheet that
will be cut by cutting head 130.
[0049] First cutting material 116 may be formed from a self-healing material
such as
felt with or without appropriate backing material. Other self-healing
materials known in
the art may also be used. First cutting material 116 in one embodiment extends
over a
top portion of cutting table 112 extending over a first or front roller, under
a portion of
4
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
the cutting table 112 and over a second rear roller. In this manner, cutting
surface
forms a continuous surface that may be moved about the table in a continuous
manner.
This continuous feature allows very long rolls or sheets longer than the
cutting machine
of materials 134 to be moved fore and aft relative to cutting table 112 and
then moved
from a front portion 138 toward a rear portion 140 and then off to a storing
location that
is off of cutting table 112 in a vector direction from front portion 138
toward rear
portion 140. Cutting material 116 is moved along they axis by a first and
second roller
positioned proximate the front 138 and rear 140 respectively of cutting table
112.
[0050] Cutting table 112 includes an aluminum honeycomb support surface with
holes
through which a vacuum system is acts. When the vacuum system is operating a
vacuum is created within cutting table 112 that acts through the cutting
material 116
upon the sheet material that is resting on an exposed surface of the cutting
material to
inhibit the sheet from moving relative to the cutting material 116. In a
traditional setup
cutting system includes a plurality of legs that rest upon a floor or support
and act to
maintain cutting table above the floor. The floor is positioned below the
vacuum
surface. The term "below" as used herein to describe a relative position such
that
below is in the direction of gravity and up is opposite the direction of
gravity.
[0051] Cutting material 116 has an exposed surface 242 and an opposing
unexposed
surface. In one embodiment cutting material 116 forms a continuous belt where
a
portion of the exposed surface faces in a direction away from table 112 and
the
opposing surface faces toward the table 112. Cutting material 116 forms a
continuous
belt so as cutting material 116 is moved about the table the exposed surface
will face
away from the direction of gravity and when the portion of the cutting
material 116
moves about the first roller and the exposed surface will face toward the
direction of
gravity when the portion of cutting material is located below table 112.
[0052] First cutting material 116 may be a self-healing material which as used
herein is
any material which is designed to endure repeated impacts from a mechanical
blade
without serious functional deterioration. By way of example a blade supported
by
cutting head is made to cut through a sheet supported by first cutting
material 116 and
extend into first cutting material 116. Material 116 is formulated from a
material such
that a cut into the first cutting material 116 allows continued use of the
first cutting
material 116 for subsequent operations where a blade cuts additional sheets
being
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
supported by first cutting material 116. Sheets may be paper, cardboard,
cloth, plastic
or other material typically used in advertising but may be used in other
applications as
well. First cutting material 116 is often referred to as a gray belt in the
machine cutting
business. A workpiece supporting surface is described in US Patent 5,141,212
as being
a foam sheet formed of "reticulated open cell polyurethane foam" and "where
the foam
is charcoal grey in color." A cutting material support is also described in US
Patent
6,945,645 as including but not limited to elastomers and plastics, self-
healing mat
material, neoprene, rubber and polyurethane.
[0053] Cutting head 128 may also include a laser cutter directing the output
of a high-
power laser, by computer, at the sheet 134 of material to be cut. Portions of
sheet 134
are then either melts, burns, vaporizes away, or is blown away by a jet of gas
leaving an
edge with a high-quality surface finish. Since a laser operates at an elevated
temperature, self-healing cutting surfaces 116 known in the art may also be
melted,
burned or vaporized away. In one embodiment a second cutting material 142
having a
higher melting and burning temperature point may be used with cutting table
112. The
movement of a cutting head relative to a cutting material is well known in the
art.
Cutting head 130 may be moved in an x-y direction by movement of cutting head
along
horizontal rail and by moving the horizontal rail along the vertical rails. It
is also
possible to include other controls to provide an angular tilt from the z axis
so the
cutting tool cuts sheet 134 at an angle other than perpendicular to the plane
defined by
the top surface 136 of sheet 134. Cutting head 130 may also move in an up/down
direction along the z axis to move a cutter toward and away from first and or
second
cutting material 116, 142.
[0054] Referring to FIG. 2, second cutting material 142 is loaded onto cutting
table 112
from transfer station 114. In one embodiment second cutting material 142 is
formed
from a plurality of metal slats 144 movable connected to one another with a
connector
146. Referring to FIG. 6 connector 146 is a flexible ribbon that is connected
to each
slat 144 with a rivet 155, through an opening 153, or other connector known in
the art
to operatively secure each slat 144 together to form the second cutting
material 142. In
one embodiment metal slats 144 are formed from an aluminum material or
aluminum
alloy or other material having a melting and burning temperature above that of
the heat
transfer from the laser cutter to the surface second cutting material 142. In
one
6
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
embodiment, cutting table 112 includes a second drive system having a drive
belt 148
having a plurality of pins 150 extending therefrom. Each pin 150 being
removably
received in a corresponding aperture 152 of a slat 144. In one embodiment,
drive belt
148 includes a plurality of a pair of pins 150 with each pair of pins 150
being received
in a corresponding pair of apertures 152. A drive wheel 154 is driven by a
motor (not
shown) in a clockwise and counterclockwise moving drive belt in fore and aft
direction.
In one embodiment, a second drive belt is positioned parallel and spaced form
first
drive belt 148 includes a plurality of pins 150 that engages corresponding
apertures 152
positioned on each slat 144 remotely from the apertures 152 that engage with
pins 150
operatively connected with first drive belt 148.
[0055] Referring to FIG. 2, transfer load station 114 is positioned relative
to cutting
table 114 and each slat is secured to the first and second drive belts by
positioning the
apertures 152 over the corresponding pints 150. Once the first slat 144 or
first few slats
144 are secured to the first and second drive belts, the drive belts maybe
driven in a
direction toward rear 140 thereby transferring all of slats 144 onto cutting
table 112. In
one embodiment, pins 150 provide a tight fit with apertures 152 thereby
allowing slats
144 to remain connected to pins 150 and the drive belts as slats 144 are moved
about a
rear roller proximate rear portion 140 and under cutting table 112. In this
manner once
all of slats 144 are transferred to cutting table 112, slats 144 make a
continuous cutting
surface that extends over an upper surface of cutting table 112 around the
rear portion
140 under a lower surface of cutting table 112 and around front portion 138.
Once all
of the slats 144 have been transferred to cutting table 112, transfer station
114 may be
moved away on roller wheels 164. In one embodiment belts 148 may be formed
from a
material such as para-aramid synthetic fiber sold under the trademark Kevlar.
Slats 144
may be removed from cutting table 112 and transferred to transfer station 114
in a
reverse manner. Pins 150 are removed from a first slat or leading edge slat
and
positioned within transfer station 114, drive belts 148 are moved in a
direction such that
the slats are moved from the belts 148 into transfer station 114.
[0056] Referring to FIG. 5 each slat 144 includes a first longitudinal edge
158 and a
second longitudinal edge 160 spaced from and generally parallel to first
longitudinal
edge 158. In one embodiment not shown longitudinal edges 158, 160 may be
beveled
such that when slats 144 are in the flat parallel orientation a portion of
edge 158 is
7
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
below the corresponding edge 160 of an adjacent slat. In this manner the laser
is fully
blocked from a laser beam extending between adjacent slats 144. Of course
other edge
geometry that provides a continuous slat surface such that a laser targeted
perpendicular
to an upper surface 162 of slat 144 would not be able to pass through a region
between
adjacent slats 144.
[0057] In one embodiment first cutting material 116 moves along with second
cutting
material 142. In another embodiment second cutting material 142 may be moved
independently of the first cutting material 116.
[0058] While second cutting surface has been described as aluminum slats,
other types
of materials are also contemplated including but not limited to a metal mesh,
a para-
aramid synthetic fiber such as that sold by Kevlar and having a melting and
burning
temperature above a corresponding temperature of the laser that may be used
for
cutting purposes. Additionally it is contemplated that the first cutting
surface include a
portion that is formed from a high heat resistant material and positioned
either to one
side (x-axis) of cutting table 114 such that a laser may be used for cutting
on one side
while a traditional blade may be used on a self-healing type of material such
as felt may
be on a second side (x-axis) of cutting table 114.
[0059] Referring to FIG. 10 in another embodiment a second cutting material
170
referred to herein as the laser cutting belt or laser belt includes aluminum
foil 174. In
one embodiment the aluminum foil 174 is between lmil (.001in) and 10mil thick
(0.010 in). In one embodiment the aluminum foil is 5 mil thick. In one
embodiment the
aluminum foil layer is between 4 mil and 5 mil thick. In other embodiments the
aluminum foil has a thickness less than lmil and in another embodiment the
aluminum
has a thickness that is greater than10 mil thick. In one embodiment the
aluminum foil
is greater than 1 mil thick. In one embodiment the aluminum foil 174 is
mounted,
adhered or laminated to a carrier material 176. In one embodiment the carrier
material
176 is one of polyurethane, fiberglass, or other similar materials. The
carrier material
in one embodiment is between 1 - 3 mm thick. In one embodiment a 1 mil ¨ 10
mil
aluminum foil is sufficient to scatter the laser beam and serves as great
cutting underlay
when cutting fabrics. In one embodiment the aluminum foil may be pure aluminum
or
an alloy containing other metals.
8
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
[0060] In one embodiment the aluminum foil 174 will be perforated with a
plurality of
apertures 180 to allow air flow to hold the graphic 134 substrate in place
relative to the
second cutting material 170 as well as to remove fumes that are created from
the
cutting process. A vacuum supplied to the underside of the first cutting
material 116
draws air through the aluminum foil 174. In an embodiment in which aluminum
foil
174 is secured to a material 176, the vacuum will draw air through the
apertures in
aluminum foil 174 through the carrier material 176 and through the first
cutting
material 116.
[0061] Referring to FIG. 12 each aperture 180 is formed by punching a disk 182
from
aluminum foil 174. Disk 182 is pushed a distance from the top surface 184 of
aluminum foil 174 toward a bottom surface 186 of carrier material 176. As a
result a
gap 188 is created between aluminum foil 174 and disk 182. Disk 182 has an
upper
surface that is not co-planar with the top surface 184 of aluminum foil 174
when the
disk 182 is pushed into the carrier material 176. The arrows in FIG. 12
illustrate the
direction of air flow. This air flow caused by the vacuum that draws air from
the top
region above the top surface 184 downwardly toward bottom surface 186. This
vacuum allows a graphic sheet 134 to be cut to be held against the top surface
184 of
aluminum foil 174. In one embodiment first cutting material 116 may be moved
by
conveyor system. The second cutting material is then moved along with the
first
cutting material 116 and in turn graphic material 134 is moved with the first
cutting
material and second cutting material as well.
[0062] In one embodiment second cutting material has a thickness of 1.8 mm
measured
along a vector direction from top surface 184 perpendicularly downward to ward
bottom surface 186. In one embodiment disk 182 is positioned half way between
upper
surface 184 and bottom surface 186. In one embodiment the location of disk 182
is
more than or less than 50% of the distance between upper surface 184 and
bottom
surface 186. The location of disk 182 must provide a sufficient annular
opening 188 so
that the vacuum can adequately retain graphic sheet 134 against the upper
surface 184
during the cutting operation and/or during movement of the second cutting
surface
about the rollers in the y vector direction as illustrated in FIG 14.
[0063] The combined carrier layer 186 and aluminum foil layer 174 is
sufficiently
flexible, that they can rolled around the rollers at each end of the cutting
machine and
9
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
act as a conveyer system to transport the fabric thru the system. The combined
carrier
layer 186 and aluminum foil layer 174 is placed on top of the first cutting
surface or
primary bel belt which is used for knife cutting. When the operator wishes to
switch
from laser cutting, he/she will simply remove the combined carrier / aluminum
foil and
now the primary belt is used for blade cutting. While aluminum is identified
as the foil
material other materials may also be used. Note that the aluminum foil may
have other
thicknesses than indicated herein. Also the substrate may be other materials
such as but
not limited to fiberglass.
[0064] Aluminum foil layer 174 is bonded to carrier layer 176 through at least
one of
pressure and heat. The application of pressure and/or heat creates a bond
layer 178
between the carrier layer 176 and aluminum foil layer 174. The carrier layer
may be
treated with an adhesive intermediate the carrier layer and the aluminum foil
layer, or
the carrier layer may be formed of a material that bonds to the aluminum foil
layer with
the application of pressure and/or heat. For example in one embodiment the
carrier
layer includes a polyurethane material that melts under the application of
pressure
and/or heat and bonds to the aluminum foil. Such a bonding process results in
a
bonded material that does not significantly wrinkle as the composite carrier
material
and bonded aluminum foil is rolled about the system. The term wrinkle as used
herein
means a permanent crease or other raised or lowered ridge on the surface of
the
aluminum foil that is caused by movement of the aluminum foil in the cutting
system
110 and/or movement to and from the storage module 114. It is believed that
wrinkles
are caused by different radius of top surface and lower belt surface onto
rollers causing
a compression of the aluminum layer when the belt comes off the rollers.
Wrinkles may
lead to cracks in the aluminum and delamination of the aluminum from the
carrier.
Cracks and or delamination may lead to the laser penetrating the aluminum
layer and
burning the carrier or even then first belt.
[0065] In one embodiment apertures 180 are formed by a punch having a cross
section
between 50mi1 and 150mi1 forming aluminum foil disks 182. The punch separates
the
disk 182 from the aluminum foil 174 and moves the disk toward the bottom
surface 186
of the carrier material 176/ Disks 182 are clipped off evenly by the punch
tool, then
pressed flat halfway into the carrier material 176 belt without too much of
the carrier
material protruding on the bottom surface 186 of the carrier material. Stated
another
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
way, the movement of disk 182 into carrier material 176 may cause the bottom
surface
186 under disk 182 to protrude away from the bottom surface 186 of carrier
material
casing a dimpled effect. In one embodiment the protrusion of material is
between
20mi1 and 30mi1. It is noted that the location of disk 182 downwardly into
carrier
material 176 is greater than the distance of the protrusion as some of the
carrier
material 176 is compressed.
[0066] To allow sufficient airflow caused by the vacuum the closeness or
density
pattern of the holes 180 created by disks 182 can be high between 25%- 45% of
the
surface area of the aluminum foil 174. The open areas 180 defined by holes 180
help to
make the final construction of the belt more flexible when passing by conveyer
rollers.
The cumulative area defined by all holes 180 is referred to as the open area
of the
aluminum foil 174. In one embodiment the open area defined as a percent of the
total
area of aluminum foil 175 is between 25% and 45%. Of course it is contemplated
that
the percent area of openings 180 to the entire surface area of the aluminum
foil 174
may be less than 25% or greater than 45%.
[0067] In one embodiment the punch sizes may be 60 mil, 94 mil, and 150 mil to
create
openings of varying diameter. In one embodiment disks are 182 are circular
creating
an annular opening 188. However other noncircular disk shapes are contemplated
as
well.
[0068] In one embodiment, aperture 180 extends clear through aluminum foil 174
and
carrier material 176 such that disks 182 are completely removed from second
cutting
material 170. Maintaining disks 182 within carrier material 176 allow for a
greater
surface area of aluminum when a laser from above is being used to cut a
graphic
material 134. If disks 182 are removed completely, there is the possibility
that a laser
may travel through aperture 180 to the first cutting material 116 and would
bum as a
result. Disks 182 remaining in carrier material 176 allows for greater hole
size
providing more flexibility in the first cutting material 170 and providing for
enhanced
air flow for securing graphic sheet 134 to second cutting material 170 by the
vacuum
during the cutting process. The energy of the laser used to cut graphic sheets
is known
in the art. The second cutting material 170 has the material characteristic
that the laser
when impinging on the second cutting material 170 after cutting through the
graphic
sheet will not melt or bum the second cutting material 170. Stated another way
the
11
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
melting temperature and the burning temperature of the second cutting material
170
including the aluminum foil 172 and disks is such that the surface of the
aluminum foil
172 and disks 182 will not burn when the laser is cutting through a graphic
sheet as is
known in the art. In one embodiment the graphic sheets are the type that are
used for
in-store displays and/or posters. Graphic sheets may be paper, Styrofoam,
cardboard,
plastic or other types of display material.
[0069] Referring to FIGS 14 and 15 in one embodiment the belt is formed from a
base
substrate of fiberglass and includes a first layer of aluminum foil bonded to
the
substrate of fiberglass. The first layer of aluminum foil is bonded to the
fiberglass with
an adhesive. In another embodiment a second layer of aluminum foil is bonded
to the
first layer of aluminum with an adhesive material. In this embodiment the belt
is
formed of a base substrate formed of fiberglass, a first layer of aluminum
bonded to the
fiberglass and a second layer of aluminum foil bonded to the first layer of
aluminum
with an adhesive.
[0070] Referring to FIGS 14 and 15, the belt may include score lines or
creases that run
perpendicular to the movement of the belt. The scoring of the aluminum layer
or layers
allows the belt to be rotated about the rollers while minimizing or
eliminating creasing
of the aluminum foil layer on the belt as the belt is moved over the rollers
from a first
orientation on top of the table to a second orientation under the table.
[0071] In one embodiment the aluminum foil 174 is another metal material. In
one
embodiment the foil 174 is embossed with a pattern. The pattern may be the
pattern of
the carrier material substrate as the aluminum foil is pressed onto the
carrier material.
Alternatively a pattern may be embossed onto the aluminum foil itself It is
believed
that the embossed patter assists in scattering the laser energy.
[0072] The top aluminum foil layer assists in scattering laser energy applied
to the belt
to minimize or eliminate burn thru or residues left on the fabric being cut by
the cutting
machine by the laser. The fabric being referred to is the fabric that is on
top of the belt
and being cut by the laser.
[0073] In one embodiment, the base layer of fiberglass is woven providing
flexure
stretch and compression properties so it conveys and rolls up onto the storage
module
114 when not in use without causing wrinkles or dents in the top aluminum
foil.
12
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
[0074] Referring to FIG 13A storage module 114 is a bin 190 from which second
cutting material 170 may be stored in an accordion fashion. Referring to FIG
13B in
one embodiment storage module 114 is a roller system in which second cutting
material
may be stored on a roller. Roller system 192 may include motors to wind and
unwind
secondary cutting material 170 between storage module 114 and cutting table
112.
[0075] In one embodiment the aluminum layer is applied to the base layer from
a roll
having sufficient length to provide the entire length of the cutting surface.
In another
embodiment the aluminum layer is formed from a plurality of sheets that are
secured to
one another along their adjacent peripheries to form the entire length and
width of the
cutting surface.
[0076] The carrier material may be formed of a material having a high friction
to the
first cutting material conveyer belt which makes indexing and conveying more
precise
and reliable.
[0077] In one embodiment the apertures 180 are between lmm and 3mm in diameter
and are drilled or punched, spaced 25mm apart in both X and Y direction, thru
the
aluminum layer(s). The open, woven, carrier material allows the vacuum flow
thru it.
The vacuum serves to hold the graphic sheet 134 to be cut in position while
cutting is
taking place by a laser.
[0078] Referring to FIG. 11 in one embodiment, creasing or scoring lines are
added in
the Y (and potentially X) direction to make the belt more bendable and avoid
wrinkles,
dents, from the conveying process. Scoring of the surface of the belt may be
added to
make the aluminum surface more uneven, scattering the laser energy further. An
uneven, textured surface, can also be achieved during lamination of the
aluminum foil
to the woven fiberglass which structure will show thru using high lamination
pressure.
[0079] When a user switches to blade cutting, the user removes the
aluminum/fiberglass belt onto a roll-up device and the primary blade cutting
belt is now
exposed and ready for use. In one embodiment the laser belt is relatively
light weight so
one operator can remove it (or put it back on) with relative ease using the
roll-up/off
rack.
[0080] In one embodiment the base carrier material that the aluminum foil is
adhered to
is a Habasit Conveyor Product under the number CM100FBS and in one embodiment
the base material the base belt material that the aluminum foil is adhered to
includes a
13
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
cotton fabric having a nonwoven structure that may include a polyester scrim
on the
traction belt side. In one embodiment a 5 mil aluminum foil is adhered to the
base
material such as the Habasit material having a thickness of 65 mil with a 5
mil double
sided adhesive tape. In one embodiment a user applies a 6 ft. x 4ft tape such
as a tape
sold by Tesa or other double sided pressure sensitive adhesive made by 3M or
other
companies to stick the second cutting material to a first cutting material
such as a
standard gray conveyer belt known in the art that serves as the cutting
surface when the
second cutting material is not in use. Stated another way the second cutting
material
may be employed only when a laser is going to be used to cut a graphic
material.
Second cutting material having a metal foil and a carrier material may be
referred to as
the metal laminated laser belt or aluminum clad belt.
[0081] Second cutting material 170 has two distal ends. The two distal ends
are
removably connected together to provide a continuous belt about the cutting
table 112.
The two distal ends may be connected with a loop and fastener connector or
other
connectors known in the conveyor belt art.
[0082] A cutting machine includes a standard first cutting material or
conveyor belt to
which the aluminum clad belt is secured to and/or over. Accordingly, depending
on the
application the aluminum clad laser belt is left on the cutting machine
conveyor belt or
it is removed and stored on a storage module
[0083] In one embodiment the base material to which the aluminum foil is
secured has
sufficient porosity to allow a vacuum to extend there through. A plurality of
holes are
punched through the aluminum foil while secured to the base material. In one
embodiment holes are punched in a row every 1 inch. In another embodiment
holes are
punched in a row every 1/2 inch.
[0084] In one embodiment the aluminum foil is 4 mil thick, and the carrier
material is
125 mil thick. The apertures 180 each have a diameter of between 100 mil and
125
mil. There are enough apertures in the aluminum foil to provide between 25%
and 25%
open area. In one embodiment the top surface of disk 182 is positioned between
intermediate the top surface of the aluminum foil and the bottom surface of
the carrier
material. In one embodiment disk 182 has a planar shape and in another
embodiment
disk 182 may have a non-planar shape such as cone or other arcuate shape. The
annular opening created by the disk and the opening 180 of the apertures
provide
14
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
sufficient volume to allow the vacuum to hold the graphic sheet to the
aluminum foil
during the laser cutting operation and/or provide sufficient volume to provide
efficient
evacuation of vapors created during the laser cutting operation.
[0085] In one embodiment, the carrier includes a non-woven belt including an
upper
portion and a lower portion having a scrim mesh there between being secured
with a
polyurethane filler. In one embodiment at least part of the non-woven belt
includes
cotton. In one embodiment the non-woven belt includes primarily cotton fibers
in
combination with a polyurethane filler and/or scrim. An adhesive film is
applied to an
aluminum film forming a laminated aluminum. In one embodiment the adhesive is
a
thermal plastic polyurethane (TPU) film that is applied to an aluminum sheet
between
4-6 mil in a lamination process. In one embodiment the aluminum sheet is 5
mil. The
TPU film and aluminum film laminate may be rolled and then applied to the
carrier
material with heat and pressure to bond the aluminum / TPU laminated layer to
the
carrier. In one implementation the carrier material includes a plurality of
divots or
dimples covering its outer surface where the divot is concave extending from
one
surface toward the other surface. The lamination of the aluminum and TPU
laminate to
the carrier belt results in similar divot or dimple pattern on the aluminum
outer surface.
See the attached photograph / figures as an example.
[0086] When the laminated carrier belt, TPU and aluminum belt is rolled over a
6 inch
diameter conveyor belt roller the aluminum layer does not wrinkle or crimp or
delaminate. The composite belt is then perforated from the back side. A
plurality of
perforations are made through the carrier, TPU and aluminum laminate from the
back
side adjacent the carrier material. Stated another way a punch enters the
carrier
material first and subsequently exits the aluminum laminate. In this way the
apertures
through the carrier material remains sufficiently open to allow air to pass
there through
in a greater volume than if the perforations were made through the aluminum
layer first
and the carrier materials subsequently. In one implementation the aperture
punch is 1.2
mm with open area of 2.5%. Stated another way the 1.2 diameter holes are
spread
across the surface of the aluminum taking up 2.5% of the area and the non
punched
regions makes up the remaining 97.5% of the surface area. The air permeates
through
the bottom surface of the cotton mate so that the perforations in the belt to
not need to
be aligned with the vacuum holes in the vacuum table.
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
[0087] In one embodiment, an adhesive layer such as a thermoplastic urethane
or
thermoplastic polyurethane (TPU) is laminated to an aluminum foil between 4
mil thick
and 6 mil thick. The TPU may be in the form of a film 1 mil thick. In one
implementation the adhesive layer is sold under the tradename DUREFLEXO PS
8000
and may be 1 mil or may be greater than 1 mil or may be less than 1 mil.
Similarly, the
aluminum foil may have a thickness less than 4 mil or greater than 6 mil
thick. Where
one mil is one thousandth of an inch. The laminated TPU film and aluminum foil
is
then laminated together with heat and pressure to a carrier / belt. In one
embodiment
the carrier belt is sold under the tradename Cottonmate0 by Habasit. In one
embodiment the Cottonmate0 belt is identified by Habasit as CM100FBS and item
number H250000350.
[0088] During the lamination process the TPU flows at least partially into the
fibers of
the carrier belt which also includes a polyurethane filler. The result is that
the final
laminate provides sufficient rigidity and flexibility for the belt, TPU and
Aluminum foil
to be wrapped around a roller without wrinkling of the aluminum foil. A
wrinkle as
used here includes any permanent folding of the aluminum layer creating a
permanent
line, ridge or depression other than a dimple or convex depression caused by
the
aluminum matching the general contour of the belt material.
[0089] Once the belt, TPU and aluminum foil is completed the three layer
laminated
materials is punched creating a plurality of 1.2 mm holes extending through
the bottom
of the belt through the top surface of the aluminum foil. In one embodiment
the punch
includes a free end which first enters the bottom surface of the belt and
subsequently
extends through the aluminum foil such that the free end of the punch extends
through
the exposed upper surface of the aluminum foil. The rate of air flow through
the
aluminum foil and belt when placed on a vacuum table when the holes are crated
with
the punch entering the belt first is greater than the rate of air flow through
the
aluminum foil and bel when the holes are crated with the punch entering the
aluminum
foil first and then entering the belt material. It is believed that the fibers
in the belt
materials are preferably aligned when the punch enters the bottom exposed
surface of
the belt first and then subsequently enters the aluminum foil. This preferred
alignment
of the fibers provides for an increased flow of air. When a laser is used to
cut a product
on the aluminum foil, TPU and belt laminated material as outlined above, the
laser does
16
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
not extend through the holes or extend through the holes sufficiently to burn
any
underlying belt or material that is supporting the aluminum, foil, TPU and
belt material.
[0090] The perforated carrier, TPU and aluminum laminated material is cut into
rolls of
130in wide belts. ALU tape is used for of laminated roll portions on a top
side of the
laminated materials and a Tesa tape is used on the opposite side. Whole belt
is then cut
into perfect rectangle (squared) and put on machine (typical size is 30ft long
x 130in
wide). The laminated carrier, TPU and aluminum layers define a laser belt that
supports a material that is to be cut by a laser. The laser belt can run on a
standard gray
cutting belt. However, the laser belt can also run without the gray belt if a
user
customer only does laser cutting and no blade cutting. The laser belt can be
removed
from the cutting equipment on to a storage roller allowing the cutting
equipment to be
used with a blade/router cutting elements.
[0091] The cutting table may be used for non-laser operations by removing the
second
laser belt and using the first cutting material as the conveyor and cutting
surface for
traditional non-laser cutting operations in which a non-metallic material may
be used.
[0092] Referring to FIG 15 cutting system 110 includes a laser cutting belt
170 formed
from a plurality of panels 200 that form a continuous laser belt. Each panel
200 is
connected to an adjacent panel with a lacing connection 202. Panels 200 have a
common length as measured along the x-axis identified in FIG. 15. In one
embodiment
panels 200 have a common width as measured along the y-axis. The length of
panels
200 is measured along an edge 204 while the width of panels 200 is measured
along an
edge 206. In one embodiment multiple panels 200 cover the top surface of table
112.
A connection strip 208 secures two adjacent panels 200 together to form a belt
that
extends over top surface of table 112 over a first roller under the table 112
and over a
second roller. The connection strip 208 may be fabricated to ensure that laser
belt 170
fits a particular cutting machine geometry 110. The width of edge 214 of
connection
strip 208 may be varied while the layers that form strip 208 are the same as
panels 200
as described herein. Individual panels 200 can be replaced if one is damaged
or if the
belt needs to be a different length. The modular panel assembly makes it fast
and easy
to build belts in different lengths. Panels may be stored in a flat planar
orientation until
a belt needs to be assembled after which the belt may be stored on roller.
17
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
[0093] Referring to FIG 15 a first cutting belt 116 extends over table 112.
Table 112
includes a top portion having a fixed aluminum honeycomb surface with vacuum
holes.
The first cutting belt rides over this fixed surface. A vacuum is applied to
the top
portion pulling air through the first cutting belt into the vacuum holes in
the top portion.
[0094] In one embodiment roller 212 is driven by a motor and roller 210 is an
idler
roller that freely rotates about its longitudinal axis. The position of first
cutting belt
116 is moved about the y-axis by rotation of roller 212. Laser Belt 170 is
positioned on
the first cutting belt and driven by movement of the first cutting belt.
[0095] Referring to FIG 16 lacing 202 includes a first portion 216 that is
secured to a
first longitudinal edge of each panel 200 and a second portion 218 that is
secured to a
second longitudinal edge of each panel 200 where the second longitudinal edge
is
spaced rom and parallel to the first longitudinal edge of each respective
panel. First
portion 216 and second portion 218 are similarly secured to a first
longitudinal edge
and second longitudinal edge of connecting strip 208. A connecting rod 220 is
removably received in a plurality of openings 222 and openings 224 in
respective first
portion 216 and second portion 218. In this manner adjacent panels 200 are
secured to
one another. Note that first portion 216 and second portion 218 are able to
pivot about
connecting rod 220 as the laser belt rotates about rollers 212 and 210. The
gaps
between the various components of first portion 216 and second portion 218 as
viewed
from the z-axis are between .5mm and 1 mm. This minimizes the space for the
laser
beam to get thru and cut into the first cutting material or grey below the
laser belt.
[0096] Referring to FIGs 16- FIG 18D each panel 200 and 208 include a base
layer 226
having a center portion that is woven covered by a top and a bottom portion of
nonwoven material. An intermediate layer 228 of thermoplastic polyurethane
(TPU) is
applied to a top layer of the base layer 226. A top layer of aluminum foil
having a
thickness between 4mi1 to 6 mil thick is secured to the base layer by the TPU
intermediate layer with the application of force and heat. The TPU layer 228
melts
under the force and heat and operatively bonds the aluminum layer 230 to the
base
layer 226.
[0097] Referring to FIG. 16 a schematic illustration of panel 200 not drawn to
scale
illustrates that base layer 226 as a result of its woven center layer has a
pattern that
creates dimples or depressions 236 on the aluminum layer once the aluminum
layer is
18
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
secured to the base layer 226 by the application of pressure and heat. In one
embodiment dimples 236 have a depth of lmm to .2mm and a generally round shape
at
the upper most portion of the dimple. The upper most portion of the dimple is
the area
furthest from the base layer 226 in the z direction. It is believed that the
dimple pattern
on the exposed surface of the aluminum layer helps to dissipate the energy of
the laser
that may impact the exposed aluminum surface thereby minimizing any damage to
the
laser belt 170 during a laser cutting operation.
[0098] Once the aluminum layer 230 is secured to the base layer 226 by the TPU
layer
228 a plurality of through holes are punched through panel 200. In one
embodiment
the through holes have a diameter of 1.3mm. As a result the area of each
opening at the
exposed surface of the aluminum layer of the panel 200 is 1.327 mm2
(701.3mm/2)2).
The number of through holes 238 on each panel is set such that the cumulative
area of
the opening of all the through holes is 0.6% of the entire surface area of the
panel 200.
In one embodiment the cumulative open area of the through holes is less than
1% of the
entire surface area of the panel. In one embodiment the cumulative open area
of the
through holes is less than 0.3% of the entire surface area of the panel. In
one
embodiment the cumulative open area of the through holes is greater than 1%.
[0099] The diameter of the through holes and the frequency of the through
holes are set
to minimize any delamination of the aluminum layer from the base layer while
allowing sufficient opening that a vacuum applied through first cutting
material 116
will have sufficient force to hole a sheet to be cut to the exposed surface of
laser belt
170. In one embodiment through holes 238 are arranged in a grid along the x
and y
axis where holes are positioned 15 mm apart on one of the x and y axis and off
set 7.5
mm on the other of the x and y axis.
[00100] Referring to FIG. 19 the allowable bending radius of each panel
is
greater than 3 inches. State another way the exposed surface of the aluminum
layer 230
will not wrinkle as each panel 200 travels about the 6 inch diameter rollers
210 and
212. As discussed herein the term wrinkle as used herein means a permanent
crease or
other raised or lowered ridge on the surface of the aluminum foil that is
caused by
movement of the panels 200 in the cutting system 110. Specifically movement of
each
panel 200 about rollers 210 and 212 will result in the permanent formation of
a crease
in the exposed surface of the aluminum layer 230. In this manner laser belt
170 retains
19
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
a surface free from permanent linear lines that may impede the operation of
the laser
belt during a laser cutting operation.
[00101] Referring to FIG. 17 a cross sectional view of the laser cutting
belt is
illustrated in that the upper surface of base layer 226 the TPU layer 228 and
Aluminum
layer 230 all have a similar dimple geometry.
[00102] Referring to FIG. 18A base layer 226 has a portion that has a non-
smooth pattern that is transferred to the initially smooth TPU and Aluminum
layers.
FIG 18A is schematic of base layer that in one embodiment has a smooth non-
woven
upper layer and lower layer. The dimpled pattern of the upper layer of the non-
woven
portion of the base layer is formed from the woven central portion of the base
layer
upon the application of pressure to the aluminum layer. The base layer, TPU
layer and
Aluminum layer are positioned on one anther is illustrated in FIG. 18B and
after the
application of pressure and heat panel 200 is formed with the aluminum layer
being
secured to the base layer by the TPU layer. In one embodiment no adhesive is
used to
secure the base layer TPU layer and aluminum layers together. The resultant
dimpled
patter is illustrated in FIG 18C.
[00103] Referring to FIG 16 the geometric regions 232 are schematic of
the
region formed by the woven central portion of the base layer. The geometric
regions
234 and 236 represent the geometric dimples that are formed on the Aluminum
and
TPU layers of each panel 200 and panel 208.
[00104] Cutting system 110 may be used in a first mode in which only the
first
cutting material or first cutting belt 116 is positioned on table 112. In this
mode a blade
is used to cut a sheet 134 on the exposed upper surface of first cutting
material belt or
gray belt 116. In a second mode of operation second cutting material or laser
belt 170
is added to cutting system 110. Starting with a first panel 200 a second panel
200 is
attached thereto with lacing 202 by securing first portion 216 of first panel
200 with
second portion 218 of second panel 200 with a rod 220. Subsequent panels 200
are
added until laser belt 170 extends completely about table 112 such that the
first panel
and the last panel secured to the laser belt 170 are positioned on the upper
surface of
the first cutting material. Stated another way the first panel 200 and the
last panel 200
secured to the chain of panels 200 are positioned on first cutting material
such that the
first panel 200 and last panel 200 are positioned a distance above the floor
or support of
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
the legs of the cutting equipment greater than the distance of the first
cutting material.
When the distance between the first panel 200 and the last panel 200 secured
to the belt
is less than the width of the panels 200 a connection panel 208 is formed to
conform to
the width between the first panel 200 and the last panel 200. The connection
panel 208
is secured to the first panel 200 by a connector 202.
[00105] In one embodiment laser belt 170 may be constructed on a separate
work
surface and transferred to cutting equipment 110 by transfer equipment 114
discussed
herein above. Where the transfer of laser belt 170 is positioned about first
cutting
material belt 116. In this manner it is possible to use a blade to cut a sheet
on cutting
equipment 110 by placing a sheet to be cut on first cutting material or gray
belt 116 and
the using a laser to cut a sheet to be cut by adding the laser belt to the
cutting
equipment 110. There is no need to remove the first cutting material or gray
belt when
the laser belt is added to the cutting equipment. When a user desires to use a
blade to
cut a sheet an operator will remove the laser belt 170 by disconnecting one of
the lacing
connectors 202 by removing a single rod 220 and removing the laser belt 170 by
using
transfer equipment 114. It is not necessary to remove rods 220 from each
respective
connector 220 in order to remove belt 170. A user may wind laser belt 170
about a
roller on a transfer equipment 114 as illustrated in FIG. 13B for example.
However
other transfer equipment known in the art is also contemplated to remove and
reattach
laser belt 170 from and to table 112.
[00106] Once laser belt 170 is secured to table 112 laser belt may be
moved
about table 112 in they direction by moving driven roller 212. In this manner
both the
first cutting material or gray belt 116 and the laser belt 170 are moved in
unison. In
one embodiment the friction between the bottom surface of laser belt 240 and
the
exposed surface 242 of first material or gray belt 116 is sufficient to move
laser belt
170 with first material or laser belt 116.
[00107] Second cutting material 170 has a higher melting and burning
temperature point than the first cutting material 116. The aluminum layer of
the second
cutting material 170 does not burn or melt when exposed to the laser that cuts
a sheet
positioned on exposed surface 244 of the laser belt 170. Additionally, the
diameter of
the through holes 238 and the open spaces in connector 202 are small enough as
to
21
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
minimize any damage to the first cutting material when the laser is operated
to cut a
sheet that is positioned on the exposed surface 244 of the laser belt 170.
[00108] Graphic sheet or material 134 may be a single sheet of material
having a
width and length along the x and y axis that are less than the width and
length of the
table 112. However, the graphic sheet or material may be a roll of material
where
portions of material from the roll is placed onto the first or second cutting
material belts
in a discrete fashion such that multiple graphic images are cut from the roll.
For
example a leading portion of a roll of material may be placed on the exposed
surface of
the first cutting material or second cutting material and a cutting knife or
laser cuts a
portion of the leading portion of the roll. The roll then may index along they
axis and
a subsequent cutting operation may be conducted on a second portion of the
roll to cut a
second graphic image from the roll. This may be repeated as graphic images are
cut all
along the roll as portions of the roll on placed onto the first or second
cutting materials.
[00109] While laser belt 170 can be used in a dual belt mode in which
laser belt
170 is placed over the gray belt 116 it is also contemplated that laser belt
170 may be
used on a cutting machine independently of the gray belt 116. Accordingly,
laser belt
170 as described herein may be driven along they axis directly by a drive
roller or by
other drive means.
[00110] Referring to FIG 20 and FIG 25 a cutting system 310 includes a
cutting
table 312 and laser cutting surface transfer station 314. Cutting table 312
includes a
first cutting material belt 316 and a first conveyor drive system 318
including a drive
motor, a driven roller 344 and an idler roller 346. Cutting table 312 further
includes a
cutter system 320 including a pair of side rails 322, 324 and a horizontal
rail 326
supporting a cutter 328. Horizontal rail 326 has a longitudinal axis 329 that
extends
generally perpendicular to the longitudinal axes of the side rails. Horizontal
rail 326 is
movable between a first portion 338 and a second portion 340 of table 312 The
longitudinal axis 329 of the horizontal rail 326 extends perpendicular to the
longitudinal axes 323 and 325 of the side rails 322, 324. Stated another way
the
longitudinal axis 329 of the horizontal rail 326 extends along or parallel to
the x axis as
illustrated in FIG 20 and the longitudinal axes 323 and 325 extend along or
parallel to
the Y-axis as illustrated in FIG 20.
22
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
[00111] A second belt 342 having a laser cutting surface extends over and
about
first belt 316. In one embodiment second belt 342 is removably placed about
first belt
316 via laser cutting surface transfer station 314. In one embodiment second
belt 342 is
driven solely frictional engagement to the first belt 316. First belt 316
extends over and
around a roller 344 which is driven by a motor and a idler second roller 346.
First
roller 344 is driven by a motor (not shown) while second roller 346 is an
idler roller
that freely rotates. First roller is proximate second portion 340 while second
roller is
first portion 338. A first tensioner is operatively connected to second roller
346 to
provide proper tension of first belt 316 when first belt is placed around both
first roller
344 and second roller 346. First belt forms a continuous belt around the first
roller 344
and the second roller 346. Second belt 342 is placed over first belt 316 such
that first
belt also goes about first roller 344 albeit over first belt 316 proximate
portion 340.
Stated another way first belt 316 is positioned between first roller 344 and
the second
belt 342. However, second belt 342 goes about a third roller 348 proximate
portion 338
such that second belt 342 is in direct contact with third roller 348. Third
roller 348
being further from first roller 344 than second roller 346. A second tensioner
350
operatively provides tension to second belt 316 by the movement of a lever or
handle
352 about pivot 354.
[00112] Having only one driven conveyer roller 344 in the back or portion
340
and no driven rollers in the front or portion 338 improves belt tracking and
increases
friction between the first or grey belt 316 and the second or laser belt 342.
Stated
another way there are two rollers (one driven 344 and one idler 346) that
supports and
moves the first or grey blade cutting belt 316 along back and forth along the
y-axis. In
addition, a third roller 348 in the which the laser belt 342 wraps around
assists in
tracking of the laser belt 342 with the grey belt 316. The use of a single
roller to move
both the first grey belt 316 and the second laser belt 342 on one end of the
table and the
use of two separate rollers on the other distal end of the table for the grey
belt 316 and
the laser belt 342 respectively provides for improved tracking of the belts
with respect
to roller 318. First cutting grey belt 316 and/or second laser belt 342 may be
formed of
any of the embodiments as described herein with respect to all of the belts
described
herein.
23
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
[00113] Referring to FIG 21 cutting station 328 includes a removably
attached
laser cutter 360 having a first portion 362 and a second portion 364. First
portion 362
includes a housing 364 holding a laser tube that generates a laser beam.
Second portion
364 is removably connected to housing 364 and includes a laser beam bender
assembly
366. Housing 364 has a first end 368 and a second end 370. Housing 364 has a
longitudinal axis 372 that is substantially parallel to the Y-axis of table
312 as
illustrated in FIG. 20. Note that the first portion 362 has a length dimension
along the
Y-axis that is substantially greater than the dimension along the X-axis ad
the Z-axis.
The longitudinal axis of the 372 extends substantially perpendicular to the
longitudinal
axis of the horizontal rail 326. Portion 370 extends beyond a rear face 374 of
the
horizontal rail 326. Stated another way the portion 370 of the first portion
362 of the
laser cutter is closer to portion 340 of the cutter table than the rear face
374 of the
horizontal rail. For further clarification the rear race 374 of the horizontal
rail is define
as the region of the horizontal rail that extends between the first rail and
the second rail
322, 324 that is directly over the first cutting belt 316. First end 368 is
closer to portion
338 of table 312 than a front surface 376 of horizontal rail 326.
[00114] Referring to FIG 22 a laser bracket 378 is operatively coupled to
the
cutter housing 380. First portion 362 of the laser assembly is secured to
bracket 378.
A handle 382 allows a user to remove bracket 378 from cutter housing 380.
Referring
to FIGS 23, 24 and 28 second portion 364 is coupled to first portion 362 via
bolts 382.
A laser lens holder 384 is secured to cutter housing 380 via a bracket 386.
While
second portion 364 is coupled to and stationary with respect to first portion
362 laser
lends holder 384 moves toward and away from first grey belt and second laser
belt in
the z-axis direction.
[00115] Laser device 360 is formed as a two-part assembly. First portion
362
houses a laser tube provides a laser exiting the first portion 362 immediately
adjacent to
the second portion 364. The laser beam exits first portion 362 in the y-axis
direction
and enters into laser lens holder of the second portion 364 which changes the
direction
of the laser beam from traveling along the Y-axis to along the Z-axis in a
direction
toward the first grey belt 316 and the second laser belt 318. A collimator is
positioned
within the second portion to adjust the diameter of the laser beam that
impacts the
surface of the item to be cut that is resting on the second laser belt 318.
The assembly
24
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
of the laser beam bender assembly and the laser lens holder assembly are
illustrated in
FIG 27 and FIG 28 respectively. It is believed that the collimator provides
enhanced
stability of the laser beam diameter for cutting purposes.
[00116] First belt 316 may be formed from a self-healing material such as
felt
with or without appropriate backing material. Other self-healing materials
known in the
art may also be used. First belt 316 in one embodiment extends over a top
portion of
cutting table 312 extending over a roller 344, under a portion of the cutting
table 312
and over roller 346. In this manner, a cutting surface forms a continuous
surface that
may be moved about the table in a continuous manner. This continuous feature
allows
very long rolls or sheets longer than the cutting machine of materials to be
moved fore
and aft relative to cutting table 312 and then moved from a first front
portion 338
toward a second portion 340 and then off to a storing location that is off of
cutting table
312 in a vector direction from first portion 338 toward second portion 340.
[00117] Second laser belt 342 may be formed as discussed with respect to
other
embodiments herein above or as further described herein below. Second laser
belt 342
has a first surface 390 and an opposing second surface 392. The second surface
392 is
immediately adjacent a first surface 394 of belt 316, while a second surface
396 that is
opposite to first surface 394 of belt 316 contacts rollers 344 and 346. Second
surface
392 of laser second belt 390 contacts first surface 394 of the first belt 316.
Second
surface 392 does not contact the majority of first roller 344 directly.
Although it is
contemplated that a portion of second belt 390 at its terminal edges 398, 399
may
contact roller 344 directly. Second laser belt 342 does however directly
contact roller
348. Second laser belt 342 is driven about table 312 by a friction contact of
the first
belt 316 and the second belt 342 by driven roller 344. Proper tension is
provided
between the two belts by adjusting the tension individually and separately of
the first
grey belt 316 and the second laser belt 348 by adjustment of rollers 346 and
348 along
the Y-axis respectively.
[00118] Referring to FIG 32 in one embodiment laser belt 342 is formed
from a
plurality of panels that are connected together as described above herein. Two
of the
panels however may be connected to one another by an industrial metal zipper.
One of
the panels may be shorter than the rest in the Y-axis direction to aid in the
connection
of the two terminal ends of the belt to form a continuous loop of material. In
one
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
embodiment belt 342 is made up of a plurality of panels having a distance of
43 inches
along the y-axis when the panel is fully parallel to the x-y plane. The short
connection
panel having one portion of the zipper assembly has a distance of 24 inches
along they-
axis when the short connection panel is in fully parallel to the x-y plane.
Other panel
lengths are contemplated. In one embodiment the panels have substantially the
same
dimension in the x-axis y-axis directions with one connection panel being
different than
the others in the y-axis direction. In one embodiment the connection panel is
shorter
than the other panels and in one embodiment the connection panel is longer
than the
other panels. It another embodiment all of the panels would be of equal
dimensions.
The connection panel may have a leading edge with one half of the zipper
assembly
that is zipped tougher to a trailing edge of another panel that includes the
other half of
the zipper assembly. The respective zipper halves may be sewn into the
respective
edges of the connector panel and other panel.
[00119] In one embodiment the zipper is heavy duty and constructed to
support a
load of 1001bs per inch. The rest of the connectors for the other panels use
metal belt
lacing as described herein above.
[00120] After assembly of the zipper, a user adds a layer of 2mi1 x 2in
3M
pressure sensitive aluminum tape (disposable) which protects the zipper and
the sewing
(stitches) from getting cut apart by the laser. The tape is simply pulled off
and disposed
when laser belt is being removed. Other high temperature resistant tapes known
in the
art that will not burn for a standard laser beam known in the cutting art may
also be
used.
[00121] Referring to FIG 29 and FIG 30 the construction of the plurality
of the
panels that form laser belt 342 includes in one embodiment a carrier or base
layer 402
and an aluminum layer 404 operatively connected to the base layer via an
adhesive 406
that is applied to the Aluminum layer 404 prior to adhesion to the base layer
402. In
this manner the adhesive 406 is positioned between the aluminum layer 404 and
the
base layer 402. In another embodiment a layer of TPU material 408 is located
between
the base layer 402 and the aluminum layer 404 as described herein above. An
adhesive
material 406 may be applied to the TPU 408 material and/or the aluminum
material 404
to increase the adhesion of the aluminum material 404 to the TPU material 406.
26
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
[00122] In one embodiment the adhesive 406 applied either directly
between the
base layer 402 and the aluminum layer 404 or between the TPU layer 408 and the
aluminum layer 404 is sprayed onto the side of the aluminum layer 404 that
faces the
TPU 406 and/or base layer 402 in a liquid form prior to adhering the aluminum
material 404 to the TPU layer 408 or the base layer 402. The types of
materials and
thickness of the materials are as discussed hereinabove.
[00123] Referring to FIG 31 in one embodiment a second layer of adhesive
is
applied between the base layer 402 and the TPU layer 408 in addition to the
first layer
406 between the aluminum layer and the TPU layer.
[00124] The adhesive provides a peel strength of at least 5 lbs/in -when
measured using ASTM peel strength tests. Once such test includes moving the
belt
about a pair of rollers roller having a diameter of 4 inches for 5000 cycles.
Other roller
diameter and cycles are also contemplated.
[00125] In one embodiment in which the adhesive 406 is applied directly
to the
TPU 408. The adhesive 406 is used to improve the bond strength between the TPU
film
408 and the Aluminum foil 404 has an aqueous based heat sealing agent. The
adhesive
agent is applied onto Aluminum surface in wet state and run through hot air
oven to
evaporate moisture. It is believed that the adhesive application assists in
lowering the
surface energy at the metal interface and thus improve bond strength with TPU
film in
laminate.
[00126] In one embodiment longitudinal edges 398 and 399 of the laser
belt 342
are covered with a fabric style tape to provide additional strength to the
edges and to
minimize peeling of the aluminum layer from the TPU and/or base layer.
[00127] In one embodiment a plurality of holes are punches through the
panels
as discussed herein above. In one embodiment the holes punches form a random
pattern to minimize the number of holes that fall in a single line that is
parallel to the x-
axis. By minimizing he number of through holes that are in a single line
cracking
and/or delamination of the aluminum layer adjacent the holes is minimized in
contrast
to the hole pattern in which all of the holes are positioned in evenly spaced
parallel
lines.
[00128] In one embodiment a cutting apparatus comprises a cutting table
and a
laser belt movably supported about the cutting table about a first roller and
a second
27
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
roller, the laser belt movable along a direction of travel extending
perpendicular to the
first roller and the second roller. A horizontal rail extends across the
cutting table
substantially between and parallel to a longitudinal axis of the first roller
and second
roller. A laser assembly includes a first portion having a laser tube
operatively secured
to the horizontal rail and a second portion operatively secured to the first
portion, the
second portion including a laser beam bender assembly. The first portion of
the laser
assembly includes a housing having a longitudinal axis parallel to the
direction of travel
of the laser belt.
[00129] In one embodiment the cutting apparatus the second portion of the
laser
assembly bends a laser beam generated from the first portion from a horizontal
direction to a vertical direction toward the laser belt.
[00130] In one embodiment the cutting apparatus further includes a
cutting
station movably supported along the horizontal rail, the cutting station
including a
bracket, the first portion of the laser assembly being coupled to the bracket.
[00131] In one embodiment the cutting apparatus further including a
handle
operatively secured to the bracket.
[00132] In one embodiment the cutting apparatus further including a
handle
operatively secured to the first portion of the laser assembly.
[00133] In one embodiment the handle, bracket and first portion of the
laser
assembly are removed together from the cutting station.
[00134] In one embodiment a bracket is operatively secured to the
horizontal rail
and the housing of the first portion of the laser assembly being removably
secured to
the bracket.
[00135] In one embodiment the housing includes a first end and a second
end,
the first end extending beyond a rear face of the horizontal rail and the
second end
extending beyond a front face of the horizontal rail.
[00136] In one embodiment the second portion of the laser assembly is
removably connected to the first portion of the laser assembly.
[00137] In one embodiment the second portion of the laser assembly
includes a
collimator adjusting the diameter of the laser beam that impacts the surface
of an item
to be cut that is resting on the laser belt.
28
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
[00138] In one embodiment a first material belt is movable about the
cutting
table between the table and the laser belt in the same direction of travel as
the laser belt.
[00139] In one embodiment a cutting station operatively is movably
supported
on the horizontal rail, the cutting station includes a bracket and the laser
assembly
being removably coupled to the bracket.
[00140] In one embodiment a longitudinal axis of the second portion is
substantially perpendicular to a longitudinal axis of the first portion.
[00141] In one embodiment the cutting apparatus further includes a laser
lens
holder operatively coupled to the second portion, the laser lens holder
operatively
supported to the cutter housing via a laser lens holder bracket.
[00142] In one embodiment the cutter apparatus further includes an
exhaust
system supported by the laser lens holder bracket.
[00143] In one embodiment a cutting apparatus comprises a cutting table
and a
laser belt movably supported about the cutting table about a first roller and
a second
roller, the laser belt movable along a direction of travel extending
perpendicular to the
first roller and the second roller. A horizontal rail extends across the
cutting table
substantially between and parallel to a longitudinal axis of the first roller
and second
roller. A laser assembly includes a first portion having a laser tube
operatively secured
to the horizontal rail and a second portion operatively secured to the first
portion, the
second portion including a laser beam bender assembly. The bracket is movable
along
the horizontal rail. The bracket being removable from the horizontal rail
while coupled
to the at least the first portion of the laser assembly.
[00144] In one embodiment the cutting apparatus includes a cutting
station
movable along a longitudinal axis of horizontal rail, the bracket being
removably
coupled to the cutting station.
[00145] In one embodiment the cutting apparatus further includes a laser
lens
holder and an exhaust system.
[00146] In one embodiment the laser lens holder is removably coupled to
second
portion of the laser assembly.
[00147] In one embodiment the laser lens holder is operatively coupled to
the
cutting station with a laser lens holder bracket.
29
CA 03082884 2020-05-15
WO 2019/070536
PCT/US2018/053549
[00148] In one embodiment a cutting apparatus comprises a cutting table
and a
laser belt movably supported about the cutting table about a first roller and
a second
roller. A horizontal rail extends across the cutting table. A laser assembly
includes a
first portion having a laser tube operatively secured to the horizontal rail
and a second
portion operatively secured to the first portion, the second portion including
a laser
beam bender assembly.
[00149] While the foregoing written description of the invention enables
one of
ordinary skill to make and use what is considered presently to be the best
mode thereof,
those of ordinary skill will understand and appreciate the existence of
variations,
combinations, and equivalents of the specific embodiment, method, and examples
herein. It is also contemplated that the features described herein may be
combined in
different combinations then described in the specific embodiments illustrated
and/or
described.
