Patent ID: 8229589
Filing Date: 2012-07-24
Classification: B23K,Y10T

Abstract:
1. A method of cutting a protective polyurethane foam material to match a predetermined design template with a laser, the method comprising the steps of: inputting the predetermined design template into a computer memory connected with a laser controller; selecting a desired thickness and density of protective polyurethane foam material as defined between a front surface and rear surface of the foam material into which the predetermined design template is to be cut with the laser; selecting a mirror power based on the thickness of the foam for the laser which defines a focal point of the laser at a desired distance from the laser along a beam axis; supporting the selected foam material adjacent an output of the laser; arranging the protective foam material adjacent the output of the laser and along the beam axis and aligning the focal point of the laser at an intermediate point between the front surface and the rear surface, and closer to the rear surface of the foam material than the front surface of the foam material, based on the mirror power selected and the thickness of the selected foam material; inputting a speed setting to the laser controller based upon at least one of the density and thickness of the foam material; energizing the laser to cut the predetermined design template into the protective foam at a speed setting determined as a function of at least one of the density and thickness of the foam material; and arranging the focal point of the laser at the intermediate point between the front surface and the rear surface of the foam material where residual laser energy beyond the focal point of the beam completes cutting through the foam material.