CN111246967A

CN111246967A - Laser system of cutting machine

Info

Publication number: CN111246967A
Application number: CN201880065525.XA
Authority: CN
Inventors: N·米克尔森; S·米克尔森
Original assignee: Mct Wisconsin LLC
Current assignee: Gerber Technology LLC
Priority date: 2017-10-05
Filing date: 2018-09-28
Publication date: 2020-06-05
Anticipated expiration: 2038-09-28
Also published as: WO2019070536A1; CN111246967B; EP3691829A1; CA3082884A1; EP3691829A4

Abstract

A cutting device, comprising: cutting table; and a laser band movably supported around the cutting table about the first and second rollers. The horizontal track extends across the cutting table. The laser assembly includes: a first portion having a laser tube operably secured to a horizontal rail; and a second portion operatively secured to the first portion, the second portion including a laser beam bender assembly.

Description

Laser system of cutting machine

Cross Reference to Related Applications

This application claims benefit of U.S. provisional application No. 62/568,654 entitled "Cutting Machinery Laser System," filed on 5.10.2017, the entire contents of which are incorporated herein by reference.

Background

The present application relates generally to the field of cutting sheets or webs with a blade and cutting sheets with a laser.

Disclosure of Invention

In one embodiment, the cutting apparatus includes a cutting table and a laser band movably supported about the cutting table about a first roller and a second roller. The horizontal track extends across the cutting table. The laser assembly includes: a first portion having a laser tube operably secured to a horizontal rail; and a second portion operatively secured to the first portion, the second portion including a laser beam bender assembly.

In one embodiment, the cutting apparatus includes a cutting table and a laser band movably supported about the cutting table about the first and second rollers, the laser band moving in a direction of travel perpendicular to the extension of the first and second rollers. The horizontal track extends across the cutting table substantially between and parallel to the longitudinal axes of the first and second rollers. The laser assembly includes: a first portion having a laser tube operably secured to a 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 ribbon.

In one embodiment, the cutting apparatus includes a cutting table and a laser band movably supported about the cutting table about the first and second rollers, the laser band moving in a direction of travel perpendicular to the extension of the first and second rollers. The horizontal track extends across the cutting table substantially between and parallel to the longitudinal axes of the first and second rollers. The laser assembly includes: a first portion having a laser tube operably secured to a horizontal rail; and a second portion operatively secured to the first portion, the second portion including a laser beam bender assembly. The carriage is movable along a horizontal rail. The carriage may be removable from the horizontal rail when coupled to at least the first portion of the laser assembly.

In one embodiment, the cutting system includes a cutting table and a first strip of cutting material movably supported about the cutting table. The second cut material is removably supported on the first cut material. The laser cut material includes a metallic material having a plurality of holes extending therefrom.

In one embodiment, a cutting system includes a cutting table and a laser cut material formed of a metallic material having a plurality of apertures extending therein.

In one embodiment, the laser cut material includes a metallic material operatively adhered to a carrier material, the metallic material having a plurality of holes formed therein and a plurality of discs directly beneath the respective holes.

A method of forming a laser cut material includes securing an aluminum foil to a carrier material and forming a hole in the aluminum foil.

In one embodiment, the cut material comprises a plurality of sheets, wherein each sheet comprises a base layer and an aluminum layer secured to the base layer. Each board is secured to an adjacent board by a connector.

Drawings

The present application will become more fully understood from the detailed description to follow, taken in conjunction with the accompanying drawings, wherein like reference numerals refer to like elements, and wherein:

FIG. 1 is a top isometric view of a cutting system with a surface loader.

Fig. 2 is a top isometric view of the cutting system of fig. 1 with the surface loader in a second engaged position.

FIG. 3 is a top isometric view of the cutting system of FIG. 1 with a surface layer loaded onto a table.

Fig. 4 is a front view of the cutting system of fig. 3.

Fig. 5 is a view of a portion of the surface of fig. 3.

FIG. 6 is a close-up view of FIG. 3 taken generally along area 6-6.

Fig. 7 is a cross-sectional view taken generally along line 7-7 of fig. 6.

Fig. 8 is a cross-sectional view taken generally along line 8-8 of fig. 6.

Fig. 9 is a cross-sectional view taken generally along line 9-9 of fig. 8.

Fig. 10 is an isometric view of the surface material.

Fig. 11 is an isometric partial view of a surface material having a score extending across the surface material.

FIG. 12 is a cross-sectional view of the surface material taken generally along line 12-12 of FIG. 10.

Fig. 13A is a surface material loading station in one embodiment.

Fig. 13B is a surface material loading station in a second embodiment.

Fig. 14 is a top isometric view of the cutting system with the surface material on the conveyor material and the graphic material on the surface material.

FIG. 15 is a top isometric view of a cutting system with a laser cut tape on top of a first cut tape.

FIG. 16 is a partial cross-sectional view of a laser cut tape and a first cut tape.

FIG. 17 is a cross-sectional view of the laser-cut tape and the first cut tape taken generally along line 17-17 of FIG. 16.

Fig. 18A is an exploded view of the laser cut tape prior to assembly.

Figure 18B is a side view of a laser cut tape layer prior to application of heat and pressure.

Fig. 18C is a side view of the laser cut tape after application of heat and pressure.

FIG. 18D is a side view of the laser-cut tape after perforation.

FIG. 19 is a schematic illustration of a laser cut tape bent at an angle having a radius.

Fig. 20 is an embodiment of a cutting system.

Fig. 21 is a close-up of the cutting head of the system of fig. 20.

Fig. 22 is a close-up of the laser carriage of fig. 21.

Fig. 23 is an isometric view of the laser beam bender assembly of fig. 21.

Fig. 24 is an isometric view of the laser expander of fig. 21.

Fig. 25 is a close-up of the tensioner system of the dual idler roller system of fig. 20.

Figure 26 is a view of a laser tube.

Fig. 27 is an exploded view of a laser beam bender assembly.

Fig. 28 is a laser lens holder and expansion assembly.

FIG. 29 is a cross-sectional exploded view of a laser cut tape.

FIG. 30 is a cross-sectional exploded view of a laser cut tape.

FIG. 31 is a cross-sectional exploded view of a laser cut tape.

FIG. 32 is a view of a zipper connector for a laser strap.

Detailed Description

Referring to FIG. 1, the cutting system 110 includes a cutting station 112 and a cutting surface transfer station 114. The cutting station 112 includes a first cutting material 116 and a first conveyor system 118. The cutting station 112 also includes a cutter system 120, which cutter system 120 includes a pair of

side rails

122, 124 and a horizontal rail 126 supporting a cutter 128. The cutter 128 includes a cutting head 130, and the cutting head 130 may include a cutting tool such as a blade, router, or other similar cutting tool known in the art. The cutting head 130 may also include a sensor 132, such as an optical detector, including but not limited to a CCD camera as known in the art, to assist in positioning the sheet 134 to be cut. In one embodiment, a vacuum system is provided to draw air into the table through the top surface of the first cut material 116 to help maintain the positioning of the sheet 134 relative to a portion of the surface of the first cut material 116. Wherein the sheet 134 is a sheet to be cut by the cutting head 130.

The first cut material 116 may be formed from a self-healing material such as a felt with or without a suitable backing material. Other self-healing materials known in the art may also be used. In one embodiment, the first cut material 116 extends over the top of the cutting table 112, extending above the first or front roller, below a portion of the cutting table 112, and above the second back roller. In this way, the cutting surface forms a continuous surface that can be moved around the table in a continuous manner. This continuous feature allows a very long web or sheet of material 134, longer than the cutter, to move back and forth relative to the cutting station 112, then from the front 138 toward the rear 140, and then away and reach a storage position that exits the cutting station 112 in a vector direction from the front 138 toward the rear 140. The cut material 116 is moved along the y-axis by first and second rollers positioned proximate the front 138 and rear 140 of the cutting table 112, respectively.

The cutting table 112 includes an aluminum honeycomb support surface with holes through which the vacuum system acts. When the vacuum system is operating, a vacuum is created within the cutting station 112 that acts on the sheeting through the cut material 116, which is disposed on the exposed surface of the cut material to prevent the sheeting from moving relative to the cut material 116. In a conventional arrangement, the cutting system comprises a plurality of legs which are placed on the floor or support and which serve to keep the cutting deck above the floor. The floor is located below the vacuum surface. The term "below" as used herein is used to describe a relative position such that below is in the direction of gravity and above is opposite to the direction of gravity.

The cut material 116 has an exposed surface 242 and an opposite unexposed surface. In one embodiment, the cut material 116 forms a continuous strip with a portion of the exposed surface facing away from the table 112 and the opposite surface facing the table 112. The cut material 116 forms a continuous strip such that as the cut material 116 moves around the table, the exposed surface will face away from the direction of gravity when a portion of the cut material 116 moves around the first roller and will face towards the direction of gravity when a portion of the cut material is below the table 112.

The first cutting material 116 may be a self-healing material, which is used herein as any material designed to withstand repeated impacts from a mechanical blade without significant functional degradation. For example, a blade supported by the cutting head is made to cut through the sheet supported by the first cut material 116 and extend into the first cut material 116. The material 116 is made of a material such that the cut into the first cut material 116 allows the first cut material 116 to continue for a subsequent operation in which the blade cuts other sheets supported by the first cut material 116. The sheet material may be paper, cardboard, cloth, plastic or other materials commonly used in advertising, but may also be used for other applications. In the mechanical cutting industry, the first cut material 116 is commonly referred to as a gray tape. The workpiece support surface is described in us patent 5,141,212 as a foam sheet formed from "reticulated open-cell polyurethane foam", and "wherein the foam is charcoal grey". Cut material supports are also described in U.S. patent 6,945,645, including but not limited to elastomers and plastics, self-healing mat materials, neoprene, rubber, and polyurethane.

The cutting head 128 may also include a laser cutter that directs the output of a high power laser through a computer to the sheet 134 of material to be cut. Portions of the sheet 134 are then melted, burned, vaporized, or blown away by the gas jets, leaving an edge with a high quality surface finish. Since the laser operates at high temperatures, the self-healing cutting surface 116, as is known in the art, may also melt, burn, or vaporize. In one embodiment, a second cutting material 142 having a higher melting point and firing temperature point may be used with the cutting table 112. The movement of the cutting head relative to the cut material is well known in the art. The cutting head 130 may be moved in the x-y directions by moving the cutting head along a horizontal track and by moving the horizontal track along a vertical track. Other controls may also be included to provide an angular tilt relative to the z-axis such that the cutting tool cuts the sheet 134 at a different angle than perpendicular to a plane defined by the top surface 136 of the sheet 134. The cutting head 130 may also be moved in an up/down direction along the z-axis to move the cutter toward and away from the first cut material 116 and/or the second cut material 142.

Referring to fig. 2, a second cut material 142 is loaded from the transfer station 114 onto the cutting station 112. In one embodiment, the second cut material 142 is formed from a plurality of metal slats 144 movably connected to one another by connectors 146. Referring to FIG. 6, connector 146 is a flexible band connected to each of the strips 144 by rivets 155 through openings 153 or other connectors known in the art that operatively secure each of the strips 144 together to form second cut material 142. In one embodiment, the metal slats 144 are formed of an aluminum material or an aluminum alloy or other material having a melting and combustion temperature that is higher than the melting and combustion temperature of the heat transfer from the laser cutter to the surface second cut material 142. In one embodiment, the cutting station 112 includes a second drive system having a drive belt 148 with a plurality of pins 150 extending therefrom. Each pin 150 is removably received in a corresponding aperture 152 of slat 144. In one embodiment, the drive belt 148 includes a plurality of pairs of pins 150, each pair of pins 150 being received in a respective pair of holes 152. The drive pulley 154 is driven by a motor (not shown) in clockwise and counterclockwise directions to move the drive belt in forward and backward directions. In one embodiment, the second drive belt is positioned parallel to and spaced apart from the first drive belt 148 and includes a plurality of pins 150 that engage corresponding apertures 152 positioned on each slat 144, the apertures 152 being remote from the apertures 152 that engage the pins 150 operatively connected to the first drive belt 148.

Referring to fig. 2, the transfer loading station 114 is positioned relative to the cutting station 114 and each slat is secured to the first and second drive belts by positioning the apertures 152 over the respective pins 150. Once the first strip 144 or the first few strips 144 are secured to the first and second drive belts, the drive belts can be driven in a rearward direction 140 to transfer all of the strips 144 to the cutting station 112. In one embodiment, the pins 150 provide a close fit with the holes 152, allowing the slats 144 to remain connected with the pins 150 and the drive belt as the slats 144 move around the rear rollers near the rear 140 and under the cutting station 112. In this manner, once all of the strips 144 are transferred to the cutting station 112, the strips 144 form a continuous cutting surface that extends around the rear portion 140 above the upper surface of the cutting station 112 and around the front portion 138 below the lower surface of the cutting station 112. Once all of the slats 144 have been transferred to the cutting station 112, the transfer station 114 may be removed by the rollers 164. In one embodiment, the band 148 may be formed of a material such as para-aramid synthetic fiber sold under the trademark Kevlar. The strip 144 may be removed from the cutting station 112 and transferred to the transfer station 114 in the reverse manner. The pin 150 is removed from the first or leading edge slat and positioned within the transfer station 114, and the belt 148 is driven in a direction that causes the slat to move from the belt 148 into the transfer station 114.

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 the first longitudinal edge 158. In one embodiment, not shown, the

longitudinal edges

158, 160 may be beveled such that a portion of the edge 158 is below the corresponding edge 160 of an adjacent slat when the slats 144 are in a flat, parallel orientation. In this manner, the laser is completely blocked from the laser beam extending between adjacent slats 144. Of course, other edge geometries of the continuous slat surface are provided such that a laser directed perpendicular to the upper surface 162 of the slat 144 will not be able to pass through the area between adjacent slats 144.

In one embodiment, the first cut material 116 moves with the second cut material 142. In another embodiment, the second cut material 142 may move independently of the first cut material 116.

While the second cutting surface has been described as an aluminum plank, other types of materials are also contemplated, including but not limited to metal mesh, such as para-aramid synthetic fibers sold by Kevlar and having melting and burning temperatures above the corresponding temperatures of the laser that can be used for cutting purposes. Additionally, it is contemplated that the first cutting surface includes a portion formed of a high heat resistant material that is positioned on one side (x-axis) of the cutting table 114 such that the laser can be used to cut on one side, while a conventional blade can be used on a self-healing type material, such as felt, that can be located on the second side (x-axis) of the cutting table 114.

Referring to fig. 10 in another embodiment, the second cut material 170, referred to herein as a laser cut tape or laser tape, includes an aluminum foil 174. In one embodiment, the aluminum foil 174 has a thickness of between 1 mil (.001 inch) and 10 mils (0.010 inch). In one embodiment, the aluminum foil is 5 mils thick. In one embodiment, the aluminum foil layer has a thickness between 4 mils and 5 mils. In other embodiments, the aluminum foil is less than 1 mil thick, and in another embodiment, the aluminum is greater than 10 mils 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 material. In one embodiment, the thickness of the carrier material is between 1-3 mm. In one embodiment, 1 to 10 mil aluminum foil is sufficient to scatter the laser beam and serve as a larger cutting mat when cutting the fabric. In one embodiment, the aluminum foil may be pure aluminum or an alloy containing other metals.

In one embodiment, the aluminum foil 174 will be perforated with a plurality of holes 180 to allow air flow to hold the graphic 134 substrate in place relative to the second cut material 170 and to remove fumes generated by the cutting process. The vacuum provided to the bottom surface of the first cut material 116 draws air through the aluminum foil 174. In embodiments where the aluminum foil 174 is secured to the material 176, the vacuum will draw air through the holes in the aluminum foil 174, through the carrier material 176, and through the first cut material 116.

Referring to fig. 12, each hole 180 is formed by punching a disk 182 out of the aluminum foil 174. The disk 182 is pushed a distance from the top surface 184 of the aluminum foil 174 toward the bottom surface 186 of the carrier material 176. As a result, a gap 188 is created between the aluminum foil 174 and the disk 182. When the disk 182 is pushed into the carrier material 176, the upper surface of the disk 182 is not coplanar with the upper surface 184 of the aluminum foil 174. The arrows in fig. 12 indicate the direction of the airflow. The airflow is caused by a vacuum that draws air from a top area above the top surface 184 down toward the bottom surface 186. This vacuum allows the graphic sheet 134 to be cut to be held against the top surface 184 of the aluminum foil 174. In one embodiment, the first cut material 116 may be moved by a conveyor system. The second cut material then moves with the first cut material 116 and, in turn, the graphic material 134 moves with the first and second cut materials.

In one embodiment, the second cut material has a thickness of 1.8mm measured in a vector direction from the top surface 184 perpendicularly downward toward the bottom surface 186. In one embodiment, the disk 182 is positioned at an intermediate location between the upper surface 184 and the bottom surface 186. In one embodiment, the position of the disk 182 is greater than or less than 50% of the distance between the upper surface 184 and the bottom surface 186. The position of the disc 182 must provide sufficient annular opening 188 so that the vacuum can sufficiently hold the graphic sheet 134 against the upper surface 184 during the cutting operation and/or during movement of the second cutting surface in the y-vector direction about the roller, as shown in fig. 14.

The combined carrier layer 186 and aluminum foil layer 174 are sufficiently flexible that they can be rolled around rollers at each end of the cutter and used as a transport system to transport the fabric through the system. The combined carrier layer 186 and aluminum foil layer 174 are placed on top of the first cutting surface or main strip for knife cutting. When the operator wishes to switch from laser cutting, he/she will simply remove the combined carrier/aluminium foil and now use the main tape for blade cutting. Although aluminum is identified as the foil material, other materials may be used. Note that the aluminum foil may have a thickness different than indicated herein. The substrate may also be other materials such as, but not limited to, fiberglass.

The aluminum foil layer 174 is bonded to the carrier layer 176 by at least one of pressure and heat. The application of pressure and/or heat creates a bonding layer 178 between the carrier layer 176 and the aluminum foil layer 174. The carrier layer may be treated with an adhesive between the carrier layer and the aluminium foil layer or the carrier layer may be formed of a material which bonds to the aluminium foil layer under the application of pressure and/or heat. For example, in one embodiment, the carrier layer comprises a polyurethane material that melts and bonds to the aluminum foil upon application of pressure and/or heat. This bonding process results in the bonding material not being significantly wrinkled as the composite carrier material and bonded aluminum foil are rolled around the system. The term wrinkle, as used herein, refers to a permanent crease or other raised or lowered ridge on the surface of the aluminum foil caused by movement of the aluminum foil in the cutting system 110 and/or to and from the storage module 114. It is believed that the wrinkles are caused by different radii of the upper and lower surfaces of the strip on the roll, resulting in compression of the aluminium layer as the strip leaves the roll. The wrinkles may cause cracks in the aluminium and delamination of the aluminium from the carrier. Cracks and/or delamination may cause the laser to penetrate the aluminum layer and burn the carrier and even then the first tape.

In one embodiment, the holes 180 are formed by a punch having a cross-section between 50 mils and 150 mils, thereby forming an aluminum foil disk 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. The discs 182 are uniformly gripped by the stamping tool and then pressed flat into one half of the strip of carrier material 176 without too much carrier material protruding onto the bottom surface 186 of the carrier material. In other words, movement of the disks 182 into the carrier material 176 may cause the bottom surfaces 186 under the disks 182 to protrude from the bottom surfaces 186 of the carrier material, thereby creating a dishing effect. In one embodiment, the protrusion of the material is between 20 mils and 30 mils. It should be noted that as some of the carrier material 176 is compressed, the disk 182 is positioned more than a protruding distance down into the carrier material 176.

To allow for sufficient airflow caused by the vacuum, the tightness or density pattern of the holes 180 created by the disk 182 may be high, between 25% and 45% of the surface area of the aluminum foil 174. The open areas 180 defined by the holes 180 help make the final configuration of the belt more flexible as it passes through the conveyor rollers. The cumulative area defined by all of the holes 180 is referred to as the open area of the aluminum foil 174. In one embodiment, the open area, defined as a percentage of the total area of the aluminum foil 175, is between 25% and 45%. Of course, it is contemplated that the percentage area of the openings 180 relative to the entire surface area of the aluminum foil 174 may be less than 25% or greater than 45%.

In one embodiment, the size of the punch may be 60 mils, 94 mils, and 150 mils to create openings of different diameters. In one embodiment, the disk 182 is circular, forming an annular opening 188. However, other non-disc shapes are also contemplated.

In one embodiment, the hole 180 extends completely through the aluminum foil 174 and the carrier material 176 such that the disc 182 is completely removed from the second cut material 170. Retaining the disk 182 within the carrier material 176 allows for a greater surface area of aluminum when the laser from above is used to cut the graphic material 134. If the disk 182 is completely removed, the laser may travel through the hole 180 to the first cut material 116 and may thus cause combustion. The disks 182 retained in the carrier material 176 allow for larger hole sizes, thereby providing greater flexibility in the first cut material 170 and providing enhanced airflow to secure the graphic sheet 134 to the second cut material 170 by vacuum during cutting. The energy of the laser used to cut the graphic sheet is known in the art. The second cut material 170 has material properties such that the laser, when striking the second cut material 170 after passing through the graphic sheet, does not melt or burn the second cut material 170. In other words, the melting temperature and the burning temperature of the second cut material 170, including the aluminum foil 172 and the disks, are such that the surfaces of the aluminum foil 172 and the disks 182 will not burn when the laser cuts through the graphic sheet as is known in the art. In one embodiment, the graphic sheet is of the type used for in-store displays and/or posters. The graphic sheet may be paper, styrofoam, cardboard, plastic, or other type of display material.

Referring to fig. 14 and 15, in one embodiment, the tape is formed from a fiberglass base substrate and includes a first aluminum foil layer bonded to the fiberglass substrate. The first aluminum foil layer is bonded to the glass fibers by an adhesive. In another embodiment, the second aluminum foil layer is bonded to the first aluminum layer by an adhesive material. In this embodiment, the tape is formed of a base substrate formed of glass fibers, a first aluminum layer bonded to the glass fibers, and a second aluminum foil layer bonded to the first aluminum layer with an adhesive.

Referring to fig. 14 and 15, the strip may include score lines or creases that extend perpendicular to the movement of the strip. The scoring of the aluminum layer or layers allows the tape to rotate about the roller while minimizing or eliminating creases in the aluminum foil layer as the tape moves from a first orientation on top of the table to a second orientation below the table above the roller.

In one embodiment, the aluminum foil 174 is another metallic material. In one embodiment, the foil 174 is embossed with a pattern. The pattern may be a pattern of the carrier material substrate when the aluminium foil is pressed against the carrier material. Alternatively, the pattern may be embossed onto the aluminum foil itself. It is believed that the imprinted pattern helps scatter the laser energy.

The top aluminum foil layer helps to scatter the laser energy applied to the tape to minimize or eliminate burn-through or residue left on the fabric that is laser cut by the cutter. The fabric referred to is a laser cut fabric on top of the belt.

In one embodiment, the substrate layer of fiberglass is woven to provide flexural tensile and compressive properties that allow it to be transported and rolled up onto the storage module 114 when not in use without causing wrinkles or indentations in the top aluminum foil.

Referring to fig. 13A, the storage module 114 is a bin 190 in which the second cut material 170 may be stored in a foldable manner. Referring to fig. 13B, in one embodiment, the storage module 114 is a roller system, wherein the second cut material may be stored on a roller. The roller system 192 can include a motor to wind and unwind the second cut material 170 between the storage module 114 and the cutting station 112.

In one embodiment, the aluminum layer is applied to the substrate layer from a roll having a sufficient length to provide the entire length of the cut surface. In another embodiment, the aluminum layer is formed from a plurality of sheets secured to one another along their adjacent peripheries to form the entire length and width of the cut surface.

The carrier material may be formed of a material having a high friction against the first cutting material conveyor belt, which makes indexing and conveying more accurate and reliable.

In one embodiment, the holes 180 are between 1mm and 3mm in diameter and are drilled or punched through the aluminum layer at 25mm intervals in the X and Y directions. The open woven carrier material allows vacuum to pass through. The vacuum is used to hold the graphic sheet 134 to be cut in place while cutting is being performed by the laser.

Referring to fig. 11, in one embodiment, creases or score lines are added in the Y (and possibly X) direction to make the tape more flexible and to avoid wrinkles, indentations, during transport. Scoring of the tape surface may be added to make the aluminum surface more uneven, thereby further scattering the laser energy. During lamination of the aluminium foil to the woven glass fibre, an uneven, textured surface can also be achieved, which structure will show up in the case of high lamination pressures.

When the user switches to blade cutting, the user moves the aluminum/fiberglass tape onto the take-up device and the main blade cut tape is now exposed and ready for use. In one embodiment, the laser tape is relatively light in weight, and therefore, can be relatively easily removed (or replaced) by an operator using the wind-up/wind-down stand.

In one embodiment the base carrier material to which the aluminum foil is adhered is a Habasit conveyor product, No. CM100FBS, and in one embodiment the base belt material to which the aluminum foil is adhered comprises a cotton fabric having a non-woven structure which may comprise a polyester scrim on the belt side. In one embodiment, a 5 mil aluminum foil is adhered to a base material having a thickness of 65 mils, such as Habasit material, by a 5 mil double-sided adhesive tape. In one embodiment, the user applies the second cut material to the first cut material, such as a standard gray conveyor belt known in the art, using 6 feet by 4 feet of tape (e.g., tape sold by Tesa or other double-sided pressure sensitive adhesive manufactured by 3M or other company) that serves as a cutting surface when the second cut material is not being used. In other words, the second cut material may be used only when the laser is to be used to cut the graphic material. The second cut material with the metal foil and the carrier material may be referred to as a metal laminate laser tape or an aluminum clad tape.

The second cut material 170 has two distal ends. The two distal ends are removably connected together to provide a continuous band around the cutting station 112. The two distal ends may be connected with loop and fastener connectors or other connectors known in the conveyor belt art.

The cutting machine comprises a standard first cutting material or conveyor belt to which and/or on which an aluminium clad belt is fixed. The aluminium clad laser band is therefore left on the cutter conveyor belt, or removed and stored in a storage module, depending on the application.

In one embodiment, the base material to which the aluminum foil is secured has sufficient porosity to allow vacuum to pass therethrough. A plurality of holes are punched in the aluminum foil while the foil is secured to the base material. In one embodiment, one row of holes is punched every 1 inch. In another embodiment, one row of holes is punched every 1/2 inches.

In one embodiment, the aluminum foil is 4 mils thick and the support material is 125 mils thick. Each aperture 180 has a diameter between 100 mils and 125 mils. The aluminum foil has sufficient holes to provide 25% to 25% open area. In one embodiment, the top surface of the tray 182 is located midway between the top surface of the aluminum foil and the bottom surface of the carrier material. In one embodiment, the disk 182 has a planar shape, and in another embodiment, the disk 182 may have a non-planar shape, such as a conical or other arcuate shape. The annular opening created by the disc and the opening 180 of the hole provide sufficient volume to allow a vacuum to hold the graphic sheet on the aluminum foil during the laser cutting operation and/or sufficient volume to effectively evacuate the vapors created during the laser cutting operation.

In one embodiment, the carrier comprises a nonwoven belt comprising an upper portion and a lower portion with a scrim web secured with a polyurethane filler therebetween. In one embodiment, at least a portion of the nonwoven belt comprises cotton. In one embodiment, the nonwoven belt consists essentially of cotton fibers combined with polyurethane fillers and/or scrims. An adhesive film is applied to the aluminum laminate forming film. In one embodiment, the adhesive is a Thermoplastic Polyurethane (TPU) film that is applied to between 4-6 mils of aluminum sheet during the lamination process. In one embodiment, the aluminum sheet is 5 mils. The TPU film and aluminum film laminate can be rolled up and then applied to a carrier material by heat and pressure to bond the aluminum/TPU laminate to the carrier. In one embodiment, the carrier material comprises a plurality of recesses or depressions covering its outer surface, wherein the recesses are concave surfaces extending from one surface towards the other surface. Laminating aluminum and TPU laminates to the carrier strip creates a similar pattern of depressions or depressions on the aluminum outer surface. Please refer to the accompanying photos/pictures as an example.

The aluminum layer did not wrinkle, curl or delaminate when the laminated carrier, TPU and aluminum strips were rotated on a 6 inch diameter conveyor roll. The composite tape is then perforated from the back side. A plurality of perforations are formed through the carrier, TPU and aluminum laminate from adjacent the back side of the carrier material. In other words, the punch first enters the carrier material and then exits the aluminum laminate. In this way, the pores through the carrier material remain sufficiently open to allow air to pass therethrough in a larger volume than the pores through the aluminum layer first and then through the carrier material. In one embodiment, the punch is 1.2mm and the open area is 2.5%. In other words, pores with a diameter of 1.2 were distributed over the surface of the aluminum, accounting for 2.5% of this area, while the non-punched area accounted for the remaining 97.5% of the surface area. Air permeates through the bottom surface of the cotton compound so that the holes in the belt do not need to be aligned with the vacuum holes in the vacuum table.

In one embodiment, an adhesive layer, such as a thermoplastic urethane or Thermoplastic Polyurethane (TPU), is laminated to an aluminum foil having a thickness of 4 mils to 6 mils. The TPU may be in the form of a 1 mil thick film. In one embodiment, the adhesive layer is under the trade name

PS 8000 is sold, and may be 1 mil, or may be greater than 1 mil, or may be less than 1 mil. Similarly, the thickness of the aluminum foil may be smallAt 4 mils or greater than 6 mils. With one mil being equal to one thousandth of an inch. The laminated TPU film and aluminum foil are then laminated to the carrier/tape by heat and pressure. In one embodiment, the carrier tape is sold under the trade name Habasit

And (5) selling. In one embodiment, Habasit will

Identified as CM100FBS and item number H250000350.

During lamination, the TPU flows at least partially into the carrier tape fibers that also contain the polyurethane filler. As a result, the final laminate provides sufficient stiffness and flexibility to the tape, TPU and aluminum foil to be wound onto a roll without wrinkling the aluminum foil. As used herein, a corrugation includes any permanent folding of the aluminum layer that produces permanent lines, ridges, or depressions rather than pits or convex depressions caused by the aluminum matching the overall profile of the strip material.

Once the tape, TPU and aluminum foil were completed, the three layer laminate was punched to form a plurality of 1.2mm holes extending through the bottom of the tape and through the top surface of the aluminum foil. In one embodiment, the punch includes a free end that first enters the bottom surface of the strip and then extends through the aluminum foil such that the free end of the punch extends through the exposed upper surface of the aluminum foil. The air flow rate through the aluminum foil and the tape placed on the vacuum table when punching with the punch entering the tape first is greater than the air flow rate through the aluminum foil and the tape when punching with the punch entering the aluminum foil first and then the tape material. It is believed that the fibers in the tape material are preferably aligned when the punch first enters the bottom exposed surface of the tape and then the aluminum foil. This preferred alignment of the fibers provides increased air flow. As described above, when a laser is used to cut products on aluminum foil, TPU and tape laminates, the laser does not extend or does not extend sufficiently through the hole, resulting in burning any underlying tape or material that supports the aluminum, aluminum foil, TPU and tape material.

The perforated support, TPU and aluminum laminate were cut into 130 inch wide rolls of tape. ALU tape was used for the laminated roll section on the top side of the laminate, while Tesa tape was used for the opposite side. The entire belt was then cut into perfect rectangles (squares) and placed on the machine (typical dimensions are 30 feet long by 130 inches wide). The laminated carrier, TPU and aluminum layer define a laser tape that supports the material to be cut by the laser. The laser band may run on a standard gray cut band. However, if the user, customer, only performs laser cutting and not blade cutting, the laser tape can also be run without the ash tape. The laser tape can be moved from the cutting device onto a storage roll to allow the cutting device to be used with a blade/router cutting element.

The cutting table may be used for non-laser operations in which non-metallic materials may be used by removing the second laser band and using the first cutting material as a conveyor and cutting surface for conventional non-laser cutting operations.

Referring to fig. 15, the cutting system 110 includes a laser cut strip 170 formed from a plurality of panels 200 forming a continuous laser strip. Each panel 200 is connected to an adjacent panel by a lace connection 202. The plates 200 have a common length measured along the x-axis identified in fig. 15. In one embodiment, the plates 200 have a common width measured along the y-axis. The length of the sheet 200 is measured along edge 204 and the width of the sheet 200 is measured along edge 206. In one embodiment, a plurality of plates 200 cover the top surface of the platen 112. The connecting strip 208 secures two adjacent plates 200 together to form a belt that extends over the top surface of the table 112, over the first roller located below the table 112, and over the second roller. The tie bar 208 may be manufactured to ensure that the laser stripe 170 is tailored to the particular cutter geometry 110. The width of the edges 214 of the connecting strips 208 may vary and the layers forming the strips 208 are the same as the layers of the panel 200 described herein. If one plate 200 is damaged or the belt needs a different length, the single plate 200 can be replaced. The modular plate assembly allows for quick and easy construction of different length belts. The plates may be stored in a flat planar orientation until it is desired to assemble the tape, after which the tape may be stored on rollers.

Referring to fig. 15, a first cutting belt 116 extends over the table 112. The table 112 includes a top having a stationary aluminum honeycomb surface with vacuum holes. A first cutting belt travels over the fixed surface. A vacuum is applied to the top portion to draw air through the first cutting belt into the vacuum holes in the top portion.

In one embodiment, roller 212 is driven by a motor, while roller 210 is an idler roller, free to rotate about its longitudinal axis. The position of the first cutting belt 116 is moved about the y-axis by rotation of the roller 212. The laser band 170 is located on the first cutting band and is driven by the movement of the first cutting band.

Referring to fig. 16, the lace 202 includes a first portion 216 secured to a first longitudinal edge of each panel 200 and a second portion 218 secured to a second longitudinal edge of each panel 200 spaced apart from and parallel to the first longitudinal edge of each respective panel. The first portion 216 and the second portion 218 are similarly secured to the first longitudinal edge and the second longitudinal edge of the connecting strip 208. The links 220 are removably received in a plurality of

openings

222 and 224 in the respective first and

second portions

216 and 218. In this way, the adjacent plates 200 are fixed to each other. Note that as the laser band rotates about

rollers

212 and 210, first portion 216 and second portion 218 are able to pivot about link 220. The gap between the various components of the first portion 216 and the second portion 218 is between 0.5mm and 1mm, as viewed from the z-axis. This will minimize the space for the laser beam to pass through and cut into the first cut material or gray zone below the laser zone.

Referring to fig. 16-18D, each

plate

200 and 208 includes a base layer 226 having a central portion covered by top and bottom weaves of nonwoven material. A middle layer 228 of Thermoplastic Polyurethane (TPU) is applied to the top layer of the base layer 226. A top layer of aluminum foil having a thickness of between 4 mils and 6 mils was secured to the substrate layer by an intermediate layer of TPU with the application of force and heat. The TPU layer 228 melts under the force and heat and operably bonds the aluminum layer 230 to the substrate layer 226.

Referring to fig. 16, a schematic illustration of the plate 200, not drawn to scale, shows that the base layer 226 as its woven central layer has a pattern that creates pits or depressions 236 in the aluminum layer once it is secured to the base layer 226 by the application of pressure and heat. In one embodiment, dimple 236 is 0.1mm to 0.2mm deep and is generally circular at the uppermost portion of the dimple. The uppermost portion of the dimple is the area farthest in the z-direction from the base layer 226. It is believed that the dimple pattern on the exposed surface of the aluminum layer helps to dissipate the laser energy that may impact the exposed aluminum surface, thereby minimizing any damage to the laser stripe 170 during the laser cutting operation.

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 the sheet 200. In one embodiment, the through holes are 1.3mm in diameter. As a result, the area of each opening at the exposed surface of the aluminum layer of the sheet 200 was 1.327mm²(π(1.3ηιτη/2)²). The number of through-holes 238 on each plate is set such that the cumulative area of the openings of all the through-holes is 0.6% of the overall surface area of the plate 200. In one embodiment, the cumulative open area of the through holes is less than 1% of the total surface area of the plate. In one embodiment, the cumulative open area of the through holes is less than 0.3% of the total surface area of the plate. In one embodiment, the cumulative open area of the through-holes is greater than 1%.

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 substrate layer while allowing sufficient opening so that the application of a vacuum through the first cut material 116 will have sufficient force to punch the sheet to be cut to the exposed surface of the laser band 170. In one embodiment, the through-holes 238 are arranged in a grid along the x and y axes, with the holes positioned 15mm apart in one of the x and y axes and offset by 7.5mm in the other of the x and y axes.

Referring to fig. 19, the allowable bend radius of each plate is greater than 3 inches. In other words, when each sheet 200 is run around

rollers

210 and 212 having a diameter of 6 inches, the exposed surface of the aluminum layer 230 will not wrinkle. As discussed herein, the term wrinkles as used herein refers to permanent creases or other raised or lowered ridges on the surface of the aluminum foil that result from movement of the sheet 200 in the cutting system 110. Specifically, the movement of each sheet 200 around the

rollers

210 and 212 will result in permanent creases being formed in the exposed surface of the aluminum layer 230. In this manner, the laser tape 170 remains a surface free of permanent linear lines that may impede the operation of the laser tape during laser cutting operations.

Referring to fig. 17, a cross-sectional view of a laser-cut tape is shown in which the upper surface of the base layer 226, the TPU layer 228, and the aluminum layer 230 all have similar dimple geometries.

Referring to fig. 18A, the base layer 226 has a portion with a matte pattern that is transferred to the initially smooth TPU and aluminum layers. Figure 18A is a schematic illustration of a substrate layer having smooth nonwoven upper and lower layers in one embodiment. Upon application of pressure to the aluminum layer, the dimple pattern of the upper layer of the non-woven portion of the base layer is formed by the woven central portion of the base layer. In fig. 18B it is shown that the substrate layer, the TPU layer and the aluminium layer are positioned to each other and after applying pressure and heat the plate 200 is formed, wherein the aluminium layer is fixed to the substrate layer by the TPU layer. In one embodiment, the base layers, the TPU layer and the aluminum layer, are secured together without the use of an adhesive. The pit pattern formed is shown in fig. 18C.

Referring to fig. 16, geometric region 232 is a schematic illustration of the area formed by the woven central portion of the substrate layer.

Geometric areas

234 and 236 represent the geometric dimples formed on the aluminum and TPU layers of each of plate 200 and plate 208.

The cutting system 110 may be used in a first mode, wherein only the first cut material or first cut strip 116 is positioned on the table 112. In this mode, the blade is used to cut the sheet material 134 on the exposed upper surface of the first strip of cutting material or ash 116. In a second mode of operation, a second cut material or laser tape 170 is added to the cutting system 110. Starting with the first panel 200, the second panel 200 is attached to the first panel 200 by the strap 202 by securing together the first portion 216 of the first panel 200 and the second portion 218 of the second panel 200 with the rod 220. Subsequent panels 200 are added until the laser stripe 170 extends completely around the table 112 so that the first and last panels secured to the laser stripe 170 are positioned on the upper surface of the first cut material. In other words, the first 200 and last 200 plates of the chain fixed to the plates 200 are positioned on the first cut material such that the first 200 and last 200 plates are positioned a distance above the floor or the support of the legs of the cutting device that is greater than the distance of the first cut material. When the distance between the first plate 200 and the last plate 200 fixed on the belt is smaller than the width of the plate 200, the connection plate 208 is formed to coincide with the width between the first plate 200 and the last plate 200. The connection plate 208 is fixed to the first plate 200 by the connector 202.

In one embodiment, the laser tape 170 may be constructed on a separate work surface and transferred to the cutting device 110 by the transfer device 114 discussed herein above. Wherein the diverter of the laser band 170 is positioned around the first band of cutting material 116. In this manner, the sheet material to be cut may be cut on the cutting device 110 using the blade by placing the sheet material to be cut on the first cutting material or gray tape 116, and cut using the laser by adding the laser tape to the cutting device 110. The laser tape is added to the cutting apparatus without removing the first cutting material or the gray tape. When the user wishes to cut the sheet using the blade, the operator will remove the laser band 170 by: one of the strap connectors 202 is disconnected by removing the single bar 220 and the laser strap 170 is removed by using the transfer device 114. The lever 220 need not be removed from each respective connector 220 to remove the strap 170. For example, as shown in fig. 13B, the user may wrap a laser band 170 around a roller on the transfer device 114. However, other transfer devices known in the art are also contemplated for removing and reattaching the laser band 170 to the table 112 from the table 112.

Once the laser tape 170 is secured to the table 112, the laser tape can be moved in the y-direction around the table 112 by moving the drive roller 212. In this manner, the first cut material or ash zone 116 and the laser zone 170 move in unison. In one embodiment, the friction between the bottom surface of the laser stripe 240 and the exposed surface 242 of the first material or gray tape 116 is sufficient to move the laser stripe 170 with the first material or laser stripe 116.

The second cut material 170 has a higher melting and combustion temperature point than the first cut material 116. The aluminum layer of the second dicing material 170 does not burn or melt when exposed to the laser that cuts the sheet located on the exposed surface 244 of the laser tape 170. In addition, the diameter of the through-hole 238 and the open space in the connector 202 are small enough to minimize any damage to the first cut material when the laser is operated to cut a sheet positioned on the exposed surface 244 of the laser band 170.

The graphic sheet or material 134 may be a single sheet of material having a width and length along the x and y axes that is less than the width and length of the platen 112. However, the graphic sheet or material may be a web material in which a portion of the material from the web is placed in a discontinuous manner on the first or second strip of cut material such that a plurality of graphic images are cut from the web. For example, the leading portion of the web material may be placed on an exposed surface of the first cut material or the second cut material, and a cutting knife or laser cuts a portion of the leading portion of the web. The web may then be indexed along the y-axis and a subsequent cutting operation may then be performed on the second portion of the web to cut a second graphic image from the web. The graphic image may be repeatedly cut along the web as portions of the web are placed on the first or second cut material.

Although the laser tape 170 may be used in a dual tape mode (where the laser tape 170 is placed on the gray tape 116), it is also envisioned that the laser tape 170 may be used for a cutter independently of the gray tape 116. Thus, the laser tape 170 described herein can be driven along the y-axis directly by a drive roller or other drive means.

Referring to fig. 20 and 25, cutting system 310 includes a cutting station 312 and a laser cutting surface transfer station 314. The cutting station 312 includes a first strip of cutting material 316 and a first conveyor drive system 318, the first conveyor drive system 318 including a drive motor, a drive roller 344 and an idler roller 346. The cutting station 312 also includes a cutter system 320, the cutter system 320 including a pair of

side rails

322, 324 and a horizontal rail 326 supporting a cutter 328. The horizontal rail 326 has a longitudinal axis 329, the longitudinal axis 329 extending substantially perpendicular to the longitudinal axis of the side rail. The horizontal rail 326 may be movable between a first portion 338 and a second portion 340 of the 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. In other words, as shown in FIG. 20, longitudinal axis 329 of horizontal rail 326 extends along or parallel to the x-axis, and as shown in FIG. 20,

longitudinal axes

323 and 325 extend along or parallel to the Y-axis.

A second tape 342 having a laser cut surface extends over the first tape 316 and around the first tape 316. In one embodiment, second belt 342 is removably placed around first belt 316 by laser cut surface transfer station 314. In one embodiment, second belt 342 is driven only in frictional engagement with first belt 316. The first belt 316 is trained over and around a motor driven roller 344 and a second idler wheel 346. The first roller 344 is driven by a motor (not shown) and the second roller 346 is a freely rotating idler roller. The first roller is proximate the second portion 340 and the second roller is proximate the first portion 338. When the first belt is placed around the first roller 344 and the second roller 346, the first tensioner is operatively connected to the second roller 346 to provide the proper tension of the first belt 316. The first belt forms a continuous belt around the first roller 344 and the second roller 346. The second belt 342 is placed on the first belt 316 such that the first belt also moves around the first roller 344, albeit on the first belt 316 near the portion 340. In other words, the first belt 316 is positioned between the first roller 344 and the second belt 342. However, the second belt 342 travels around the third roller 348 adjacent the portion 338 such that the second belt 342 is in direct contact with the third roller 348. The third roller 348 is farther from the first roller 344 than the second roller 346. The second tensioner 350 is operable to provide tension to the second belt 316 by movement of a lever or handle 352 about a pivot 354.

Having only one drive conveyor roller 344 in the rear portion or section 340 and no drive rollers in the front portion or section 338 improves tape tracking and increases friction between the first or gray tape 316 and the second or laser tape 342. In other words, there are two rollers (one drive roller 344 and one idler roller 346) that support and move the first or gray blade cut strip 316 back and forth along the y-axis. In addition, the third roller 348 around which the laser stripe 342 is wrapped helps track the laser stripe 342 with the gray stripe 316. Using a single roller at one end of the table to move the first ash belt 316 and the second laser belt 342 and two separate rollers at the other end of the table for the ash belt 316 and the laser belt 342, respectively, provides improved tracking of the belts relative to the roller 318. With respect to all of the bands described herein, the first cut ash band 316 and/or the second laser band 342 may be formed from any of the embodiments described herein with respect to all of the bands.

Referring to fig. 21, the cutting station 328 includes a removably attached laser cutter 360 having a first portion 362 and a second portion 364. The first portion 362 includes a housing 364 that houses a laser tube that generates a laser beam. The second portion 364 is removably connected to the housing 364 and includes a laser beam bender assembly 366. The housing 364 has a first end 368 and a second end 370. The housing 364 has a longitudinal axis 372, the longitudinal axis 372 being substantially parallel to the Y-axis of the table 312, as shown in fig. 20. Note that first portion 362 has a length dimension along the Y-axis that is substantially greater than the dimensions along the X-axis and the Z-axis. The longitudinal axis 372 extends substantially perpendicular to the longitudinal axis of the horizontal rail 326. The portion 370 extends beyond the back side 374 of the horizontal rail 326. In other words, the portion 370 of the first portion 362 of the laser cutter is closer to the portion 340 of the cutter table than the back side 374 of the horizontal rail. To further clarify, the back side 374 of the horizontal rail is defined as the area of the horizontal rail extending between the first and

second rails

322, 324 directly above the first cut strip 316. The first end 368 is closer to the portion 338 of the table 312 than the front surface 376 of the horizontal rail 326.

Referring to fig. 22, the laser bracket 378 is operably coupled to the cutter housing 380. The first portion 362 of the laser assembly is secured to the bracket 378. The handle 382 allows the user to remove the bracket 378 from the cutter housing 380. Referring to fig. 23, 24 and 28, the second portion 364 is connected to the first portion 362 by a bolt 382. The laser lens support 384 is secured to the cutter housing 380 by a bracket 386. When the second portion 364 is coupled to the first portion 362 and is stationary relative to the first portion 362, the laser lens support 384 moves in the z-axis direction toward and away from the first and second gray bands.

The laser device 360 is formed as a two-part assembly. The first portion 362 houses a laser tube that provides laser light away from the first portion 362 proximate to the second portion 364. The laser beam exits the first section 362 in the Y-axis direction and enters the laser lens holder of the second section 364, which changes the direction of the laser beam from traveling along the Y-axis to traveling along the Z-axis in a direction toward the first gray band 316 and the second laser band 318. A collimator is positioned within the second section to adjust the diameter of the laser beam that impinges on the surface of the article to be cut on the second laser band 318. The assembly of the laser beam bender assembly and the laser lens holder assembly is shown in fig. 27 and 28, respectively. It is believed that the collimator provides enhanced laser beam diameter stability for cutting purposes.

The first belt 316 may be formed from a self-healing material, such as a felt with or without a suitable backing material. Other self-healing materials known in the art may also be used. In one embodiment, the first strip 316 extends over the top of the cutting station 312, above the roller 344, below a portion of the cutting station 312, and above the roller 346. In this way, the cutting surface forms a continuous surface that can be moved around the table in a continuous manner. This continuous feature allows a very long web or sheet that is longer than the material cutter to move back and forth relative to the cutting station 312, then from the first front portion 338 toward the second portion 340, and then to the storage position, i.e., away from the cutting station 312 in a vector direction from the first portion 338 toward the second portion 340.

Second laser stripe 342 may be formed as discussed above with respect to other embodiments herein or as further described herein below. Second laser stripe 342 has a first surface 390 and an opposing second surface 392. The second surface 392 is immediately adjacent the first surface 394 of the belt 316, while a second surface 396 opposite the first surface 394 of the belt 316 contacts the

rollers

344 and 346. Second surface 392 of laser second strip 390 contacts first surface 394 of first strip 316. The second surface 392 does not directly contact a majority of the first roller 344. It is contemplated that a portion of second belt 390 at its

terminal edges

398, 399 may directly contact roller 344. However, the second laser stripe 342 does directly contact roller 348. Second laser stripe 342 is driven around table 312 by drive roller 344 through frictional contact of first stripe 316 and second stripe 342. The tension of the first ash belt 316 and the second laser belt 348 is individually adjusted by adjusting

rollers

346 and 348, respectively, along the Y-axis to provide the proper tension between the two belts.

Referring to FIG. 32, in one embodiment, laser stripe 342 is formed from a plurality of plates that are joined together as described above. However, the two panels may be connected to each other by an industrial metal zipper. One of the plates may be shorter than the remaining plates in the Y-axis direction to assist in joining the two ends of the strip to form a continuous loop of material. In one embodiment, the belt 342 is comprised of a plurality of plates having a distance of 43 inches along the y-axis when the plates are perfectly parallel to the x-y plane. The short webs with a portion of the zipper assembly have a distance of 24 inches along the y-axis when the short webs are perfectly parallel to the x-y plane. Other plate lengths are considered. In one embodiment, the plates have substantially the same dimensions in the x-axis and y-axis directions, with one connecting plate being different from the other plates in the y-axis direction. In one embodiment, the connecting plates are shorter than the other plates, and in one embodiment, the connecting plates are longer than the other plates. In another embodiment, all plates will be of equal size. The web may have a front edge with one half of the zipper assembly being more securely pulled to a rear edge containing the other half of the zipper assembly. The respective zipper halves may be wire-bonded into respective edges of the connector panel and the other panels.

In one embodiment, the zipper is heavy duty and is configured to support a load of 100 pounds per inch. The remaining connectors of the other boards use metal strapping as described above.

After the zipper is assembled, the user adds a 2 mil by 2 inch layer of 3M pressure sensitive aluminum tape (disposable) that protects the zipper and the sewn stitches (stitches) from being cut by the laser. When the laser tape is removed, the tape need only be pulled down and discarded. Other high temperature resistant tapes known in the art that do not burn with a standard laser beam known in the cutting art may also be used.

Referring to fig. 29 and 30, the construction of the plurality of plates forming the laser stripe 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 bonding to the base layer 402. In this manner, the adhesive 406 is positioned between the aluminum layer 404 and the substrate layer 402. In another embodiment, the layer of TPU material 408 is located between the base layer 402 and the aluminum layer 404, as described 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.

In one embodiment, the adhesive 406 is sprayed in liquid form onto the side of the aluminum layer 404 facing the TPU 406 and/or the substrate layer 402 before adhering the aluminum material 404 to the TPU layer 408 or the substrate layer 402, the adhesive 406 being applied directly between the substrate layer 402 and the aluminum layer 404 or directly between the TPU layer 408 and the aluminum layer 404. The type of material and the thickness of the material are as described above.

Referring to fig. 31, in one embodiment, a second adhesive layer 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.

The adhesive provides a peel strength of at least 5 pounds per inch when measured using the ASTM peel strength test. Such testing included moving the belt 5000 cycles around a pair of rollers having a diameter of 4 inches. Other roll diameters and cycles are also contemplated.

In one embodiment, 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 with a water based heat sealer. The adhesive was applied to the aluminum surface in a wet state and the moisture was evaporated by a hot air oven. It is believed that the application of the adhesive helps to reduce the surface energy at the metal interface and thus improves the bond strength with the TPU film in the laminate.

In one embodiment, the

longitudinal edges

398 and 399 of laser tape 342 are covered with a fabric-type tape to provide additional strength to the edges and minimize peeling of the aluminum layer from the TPU and/or substrate layers.

In one embodiment, a plurality of holes are punched through the plate, as described above. In one embodiment, the punch is patterned arbitrarily to minimize the number of holes that fall in a single line parallel to the x-axis. By minimizing the number of through holes located in a single line, cracking and/or delamination of the aluminum layer adjacent to the holes may be minimized, compared to a hole pattern where all holes are located on equally spaced parallel lines.

In one embodiment, the cutting apparatus includes a cutting table and a laser band movably supported about the cutting table about the first and second rollers, the laser band moving in a direction of travel perpendicular to the extension of the first and second rollers. The horizontal track extends across the cutting table substantially between and parallel to the longitudinal axes of the first and second rollers. The laser assembly includes: a first portion having a laser tube operably secured to a 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 a direction of travel of the laser ribbon.

In one embodiment of the cutting device, the second portion of the laser assembly bends the laser beam generated from the first portion from a horizontal direction to a vertical direction toward the laser band.

In one embodiment, the cutting apparatus further comprises a cutting station movably supported along the horizontal rail, the cutting station comprising a carriage to which the first portion of the laser assembly is coupled.

In one embodiment, the cutting device further comprises a handle operatively secured to the carriage.

In one embodiment, the cutting device further comprises a handle operatively secured to the first portion of the laser assembly.

In one embodiment, the handle, the bracket, and the first portion of the laser assembly are removed together from the cutting station.

In one embodiment, the carriage is operably secured to the horizontal rail and the housing of the first portion of the laser assembly is removably secured to the carriage.

In one embodiment, the housing includes a first end and a second end, the first end extending beyond a back side of the horizontal rail and the second end extending beyond a front side of the horizontal rail.

In one embodiment, the second portion of the laser assembly is removably connected to the first portion of the laser assembly.

In one embodiment, the second part of the laser assembly comprises a collimator which adjusts the diameter of the laser beam which impinges on the surface of the article to be cut resting on the laser band.

In one embodiment, the first strip of material is movable between the cutting station and the laser strip around the cutting station in the same direction of travel as the laser strip.

In one embodiment, a cutting table is operably movably supported on the horizontal rail, the cutting table includes a carriage, and the laser assembly is removably coupled to the carriage.

In one embodiment, the longitudinal axis of the second portion is substantially perpendicular to the longitudinal axis of the first portion.

In one embodiment, the cutting device further comprises a laser lens support operably coupled to the second portion, the laser lens support operably supported to the cutter housing via a laser lens support bracket.

In one embodiment, the cutting apparatus further comprises an exhaust system supported by the laser lens holder carriage.

In one embodiment, the cutting apparatus includes a cutting table and a laser band movably supported about the cutting table about the first and second rollers, the laser band moving in a direction of travel perpendicular to the extension of the first and second rollers. The horizontal track extends across the cutting table substantially between and parallel to the longitudinal axes of the first and second rollers. The laser assembly includes: a first portion having a laser tube operably secured to a horizontal rail; and a second portion operatively secured to the first portion, the second portion including a laser beam bender assembly. The carriage is movable along a horizontal rail. The carriage is removable from the horizontal rail when connected to at least the first portion of the laser assembly.

In one embodiment, the cutting device includes a cutting station movable along a longitudinal axis of the horizontal rail, the carriage being removably coupled to the cutting station.

In one embodiment, the cutting apparatus further comprises a laser lens holder and an exhaust system.

In one embodiment, the laser lens holder is removably coupled to the second portion of the laser assembly.

In one embodiment, the laser lens support is operably coupled to the cutting station by a laser lens support bracket.

While the above written description of the invention enables one of ordinary skill to make and use what is presently considered to be the best mode thereof, those of ordinary skill in the art will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiments, methods, and examples herein. It is also contemplated that features described herein may be combined in various combinations and then described in specific embodiments shown and/or described.

Claims

1. A cutting device, comprising:

cutting table;

a laser strip movably supported around the cutting table about first and second rollers, the laser strip movable in a direction of travel perpendicular to an extension of the first and second rollers;

a horizontal track extending across the cutting table substantially between and parallel to the longitudinal axes of the first and second rollers;

a laser assembly, the laser assembly comprising: a first portion having a laser tube operably secured to the horizontal rail; and a second portion operatively secured to the first portion, the second portion comprising a laser beam bender assembly, wherein the first portion of the laser assembly comprises a housing having a longitudinal axis parallel to the direction of travel of the laser stripe.

2. The cutting device of claim 1, wherein the second portion of the laser assembly bends the laser beam generated from the first portion from a horizontal direction to a vertical direction toward the laser band.

3. The cutting device of claim 2, further comprising: a cutting station movably supported along the horizontal rail, the cutting station including a carriage to which the first portion of the laser assembly is coupled.

4. The cutting device of claim 3, further comprising a handle operably secured to the carriage.

5. The cutting device of claim 3, further comprising: a handle operably secured to the first portion of the laser assembly.

6. The cutting device of claim 4, wherein the handle, the bracket, and the first portion of the laser assembly are removed together from the cutting station.

7. The cutting device of claim 3, further comprising: a bracket operatively secured to the horizontal rail, and the housing of the first portion of the laser assembly is removably secured to the bracket.

8. The cutting device of claim 1, wherein the housing includes a first end and a second end, the first end extending beyond a back side of the horizontal rail and the second end extending beyond a front side of the horizontal rail.

9. The cutting device of claim 1, wherein the second portion of the laser assembly is removably connected to the first portion of the laser assembly.

10. The cutting device of claim 1, wherein the second portion of the laser assembly includes a collimator that adjusts the diameter of the laser beam that impinges the surface of an item to be cut resting on the laser belt.

11. The cutting device of claim 1, further comprising: a first strip of material movable about the cutting table between the cutting table and the laser strip in the same direction of travel as the laser strip.

12. The cutting device of claim 1, further comprising: a cutting station operably movably supported on the horizontal rail, the cutting station including a carriage to which the laser assembly is removably coupled.

13. The cutting device of claim 9, wherein a longitudinal axis of the second portion is substantially perpendicular to a longitudinal axis of the first portion.

14. The cutting device of claim 11, further comprising: a laser lens support operably coupled to the second portion, the laser lens support operably supported to the cutter housing by a laser lens support bracket.

15. The cutter device of claim 13, further comprising: an exhaust system supported by the laser lens support bracket.

16. A cutting device, comprising:

cutting table;

a laser assembly, the laser assembly comprising: a first portion having a laser tube operably secured to the horizontal rail; and a second portion operatively secured to the first portion, the second portion comprising a laser beam bender assembly;

the carriage is movable along the horizontal rail;

the bracket is removable from the horizontal rail when coupled to the at least first portion of the laser assembly.

17. The cutting device of claim 16, further comprising: a cutting station movable along a longitudinal axis of the horizontal rail, the carriage removably coupled to the cutting station.

18. The cutting device of claim 17, further comprising: a laser lens holder and an exhaust system.

19. The cutting device of claim 17, wherein the laser lens holder is removably coupled to the second portion of the laser assembly.

20. The cutting device of claim 19, wherein the laser lens support is operably coupled to the cutting table by a laser lens support bracket.

21. A cutting device, comprising:

cutting table;

a laser band movably supported around the cutting table about a first roller and a second roller;

a horizontal rail extending across the cutting table;

a laser assembly, the laser assembly comprising: a first portion having a laser tube operably secured to the horizontal rail; and a second portion operatively secured to the first portion, the second portion including a laser beam bender assembly.