Infinite thickness laser processing system

A laser material processing system comprises: a housing defining an engraving chamber, an xy laser beam steering system, and a non-telescoping sliding focus mechanism. The housing includes a removable bottom panel that allows processing of workpieces that exceed dimensions of the engraving chamber and allows stacking of the system on modular attachments for specialized functions. The focus mechanism includes a carriage mirror subassembly attached to the x-axis carriage, a sliding member moveably attached to the carriage mirror subassembly, and a focusing lens subassembly attached perpendicularly to the lower end of the sliding member. The carriage mirror subassembly and the focusing lens subassembly are configured to receive and focus a laser beam to a focal point. The focusing lens subassembly is adjusted along a z-axis by disengaging the locking component and vertically sliding the sliding member and is locked into a position by engaging the locking component with the sliding member.

FIELD OF THE INVENTION

The present invention relates generally to laser material processing systems. More particularly, the present invention relates to a modular laser material processing system apparatus and focusing mechanism for a laser beam for use in cutting and engraving materials of varying thicknesses and sizes with the capability to cut and engrave materials that exceed the limited dimensions of a work area.

BACKGROUND

Laser material processing systems or laser engraving machines are capable of directing a laser in a controlled pattern in order to etch and cut materials such as acrylic, or burn and mark materials such as wood or metal. They include a laser source, beam steering apparatus, beam focusing apparatus, a controller capable of directing the position of the laser output, and a surface or workspace into which objects can be placed for the laser engraving machine to act upon them.

The output from the laser produces heat energy at the point of focus. Depending on the power of the laser and the material being engraved, the laser's energy may vaporize portions of the material or cut completely through it. With other materials or at lower power settings, the top layer of the material may be burned or charred to produce patterns, images, or words. Common materials used in engraving are plastics, wood, leather, and some types of metal.

Laser material processing systems can be controlled by home or office computer systems in a similar method to traditional ink- and toner-based printers. Using various software and device drivers, laser material processing systems can be instructed to “print” patterns using a laser, including patterns such as images, text, or shapes. The controller positions the laser head at the appropriate x-axis and y-axis positions; some controllers are also able to control the distance between the laser and the material being engraved and thus adjust the z-axis (the engraving plane) as well. Thus, laser engraving machines can be used to cut shapes from a solid sheet of acrylic, to shape blocks of wood into jewelry, or to “print” by burning patterns onto wood or leather signs, belt buckles, or wallets.

Laser engraving machines can vary from very large, industrial machines with a large workspace (the size of which limits the size of the object that can be engraved), to home models of more limited dimensions and workspace capacities. These laser engraving machines are alternately known as laser cutters, and smaller units designed for homes or garages are commonly referred to as “hobby lasers.”

Traditionally, the design of laser engraving machines includes a workspace that is enclosed to some degree. Within the workspace the output of the laser is controlled to move on x, y, and z axes. This design paradigm necessitates the size of the workspace—and hence the size of the object to be engraved—be limited by the overall size of the laser engraving machine itself. In order for the laser engraving machine to operate on an object to be engraved, that object would need to physically fit (in length, width, and height) within the confines of laser engraver. For example, a hobby laser engraving device might only be able to fit objects no more than 24 inches in length, 12 inches in width, and 6 inches deep; objects larger than these dimensions in any direction could not be engraved by a machine of such size. In the field of affordable, relatively compact, easy to ship “hobby lasers” for home use, such limitations meant that these systems could only be used for smaller projects and to engrave smaller objects.

It is standard practice within the industry to provide a method for varying the distance from the engraving plane to the focus optic in combination with a final turning mirror in order to allow a laser material processing system to process varying workpiece thicknesses. The methods used currently in the industry are either: (a) a focusing optic fixed in the vertical up-down direction (z-axis or z space) with an adjustable lower surface that moves the entire material vertically up or down in the z direction, or (b) a limited motion focusing optic in which the motion is constrained such that no part of the vertically moving mechanism can pass above the laser beam path.

The fixed focusing optic method that utilizes a lower surface that travels or moves vertically up and down (a “z table”) is deficient due to the limited range of workpiece thicknesses that can be accommodated within the engraving chamber and remain in focus. The nature of a fixed optic and movable z table requires that the z table be actuated in some manner, leading to restrictions in the range of motion of the z table for a given work area envelope and laser material processing system size. This method requires raising the z table through motorized or manual turning of lead screws or belts. This creates problems due to the additional cost and complexity of the extra motorized or manual z table along with the cost and complexity to ensure the z table is perfectly flat, requiring the need for constant adjustments after transportation. Furthermore, the additional mechanical components required for actuating the entire z table often reduces the area that can be reached by the laser beam in the horizontal left-right direction (x-axis) and/or horizontal forward-backward direction (y-axis).

A limited motion focusing optic eliminates the disadvantages of the travelling z table design but suffers from limited focusing distance because no part of the vertically moving mechanism can pass above the laser beam path. One method for making the focusing optic movable involves a telescoping lens tube in which the lens is mounted to a tube of length A, and this tube slides inside another tube of length B. The problem with this design is that the stroke is limited to length A in cases where A is less than or equal to B; or the stroke is limited to length B in cases where B is less than or equal to A. For a given work cube depth z, the maximum material thickness is limited to the difference in distance between work cube depth z and the maximum stroke length. This design is also limited to a minimum material thickness if the bottom work surface is fixed.

Another method for creating a limited motion optic utilizes a sliding mirror that is still limited because, like with a telescopic lens tube, these methods place the vertical moving/focus mechanism in-line with the final beam-steering mirror leading to limitations in vertical motion such that no part of the sliding mechanism can pass above the laser beam path.

Due to the widespread application and the growth of low-power laser material processing systems for use by small businesses, individual hobbyists, and other non-industrial users, there is a need and demand for a transportable, versatile, and affordable laser engraving system that is able to perform the same functions and engrave materials of the same sizes as larger, more expensive systems. Many laser engraving machines are comprised of cumbersome, monolithic housings, yet still provide only limited functionality and versatility. For instance, some laser processing systems are made of heavy sheet metal that is manipulated into a solid volume shape such as a box or cube; the larger the box, the larger the size of the material that can be engraved. These laser engraving systems are not only difficult and expensive to ship and transport due to their weight and large footprints, but manufacturing and assembly costs are high for such solid volumes. Also, without major modification to the main laser engraving system, such systems are not easily versatile or modular, so as to allow a part to easily be interchanged and/or an attachment to easily be added to allow customized performance of the laser material processing system for particular use applications, including use on certain types of materials, and/or specific shaped materials such as a cylindrical bottle.

Accordingly, there is a need in the art for a modular, versatile, interchangeable, and easily transportable laser processing system that: (a) includes a focusing mechanism that can effectively vary the distance from the engraving plane to the focus optic to allow the processing of varying workpiece thicknesses; (b) allows the processing of materials and workpieces that exceed the dimensions of the processing system's engraving chamber and work area (including in the z-axis); and (c) allows the user to add a variety of specialized modular attachments to perform specialized functions or to process specific types and/or shapes of materials and allows the user to easily interchange parts of the invention for increased functionality and capabilities. A laser processing system that addresses the above-mentioned drawbacks in the art would not only provide a consumer with a wide array of options for materials and workpieces to be processed, but it would be more cost-efficient since (i) a separate laser processing system apparatus would not have to be purchased to cut and engrave specific types or shapes of materials and materials that exceed workspace dimensions, and (ii) the costs for two-dimensional manufacturing and assembly of parts using flat panels would cost less than the three-dimensional manufacturing and assembly of parts for solid, monolithic volume structures of other laser processing systems. Other advantages of the present invention will be apparent to one of ordinary skill in the art in light of the ensuing description of the present invention.

SUMMARY

The present invention is directed to an affordable modular laser material processing system that includes interchangeable parts, configurable attachments, and a sliding focus mechanism that permit the cutting and engraving of various materials that exceed the dimensions of the engraving chamber.

The present invention overcomes the limitations of current laser processing systems by attaching the focusing optic to a sliding mechanism such that part of the sliding mechanism can pass above the laser beam path. The present invention allows the same focus lens travel in a more compact form factor and takes advantage of wasted z space above the horizontal left-right and forward-backward (x/y) beam steering system to gain greater maximum workpiece thickness for a given housing size. To take full advantage of the stroke length possible with the present invention, in some embodiments of the invention, the housing includes a removable bottom panel, and the sliding mechanism is dimensioned such as to make engraving or cutting workpieces below the normal work area possible. In such versions of the invention, the infinite thickness (z-axis) laser processing system can be mounted on a workpiece with dimensions that exceed the work area within the work cube in order to cut or engrave a portion of the workpiece corresponding to the normal range of x and y travel. By moving the entire laser engraving system in the x and y directions and engraving another section of the workpiece, and in conjunction with the infinite thickness (z-axis) of the workpiece, such a system can be used to engrave cars, tables, or other workpieces of virtually unlimited size in all three dimensions or axes.

The modular components and attachments and the interchangeable parts of the invention allow the performance of the laser material processing system to be customized to particular use cases or to be used with specific shapes and types of materials and workpieces. For instance, in embodiments of the invention wherein the housing includes a removable bottom panel, the laser processing system can be stacked on top of various attachments to enhance system capabilities and functionality such as part pass-through, automatic conveyor, part processing, and engraving on cylindrical surfaces. The laser material processing system of the present invention is adapted to function with various attachments to enhance its suitability for typical uses without major modification of the base system. Furthermore, the external housing of the laser processing system of the present invention is comprised of a panelized structure that costs less to manufacture, is easily transportable, can easily be disengaged wherein the bottom panel can be removed, and offers a small footprint so that the laser processing system can be placed onto any desktop, table, or other work surface.

To achieve the foregoing and in accordance with the purposes of the present invention, one aspect of the present invention is directed to a laser processing system that generally comprises: (a) a housing defining an engraving chamber, (b) an xy laser beam steering system located inside the engraving chamber, and (c) a non-telescoping focus mechanism. The xy laser beam steering system includes: (i) a first y-axis rail, (ii) a second y-axis rail parallel to the first y-axis rail, (iii) a first y-axis carriage moveably mounted to the first y-axis rail, (iv) a second y-axis carriage moveably mounted to the second x-axis rail, (v) an x-axis rail perpendicular to both the first y-axis rail and the second y-axis rail wherein one end of the x-axis rail is adjoined to the first y-axis carriage and the other end of the x-axis rail is adjoined to the second y-axis carriage, and (vi) an x-axis carriage moveably mounted to the x-axis rail. The non-telescoping focus mechanism comprises: (i) a carriage mirror subassembly attached to the x-axis carriage, (ii) a sliding member including a linear guide component and a locking component wherein the sliding member is moveably attached to the carriage mirror subassembly, and (iii) a focusing lens subassembly attached to a lower end of the sliding member. The carriage mirror subassembly and the focusing lens subassembly are configured to receive and focus a laser beam to a focal point. The focusing lens subassembly is adjusted along a z-axis of the engraving chamber by disengaging the locking component and vertically sliding the sliding member.

The linear guide component of the sliding member may include one or more slots, pins, screws and/or rails or any another suitable mechanism that linearly guides the sliding member's vertical motion and helps secure the sliding member into position. For example, in one embodiment of the invention, the sliding member is comprised of a flat plate and the linear guiding component is comprised of a first slot, a second slot, and a center slot wherein the first slot and second slot slide over locating pins to guide the sliding member, and the locking component is engaged with the center slot to hold the focusing lens subassembly at a position along the z-axis. The focusing lens subassembly includes a lens holder that is interchangeable to allow for different focal length lenses. The x-axis carriage comprises a plurality of rollers that move the x-axis carriage along the x-axis rail. The plurality of rollers comprises (i) a first fixed roller, (ii) a second fixed roller, (iii) a first eccentric roller, and (iv) a second eccentric roller wherein the first eccentric roller and the second eccentric roller can each be adjusted to align the x-axis carriage along the x-axis rail.

The housing may be comprised of (i) a left side panel, (ii) a right side panel, (iii) a front panel, (iv) a bottom panel, (v) a top member, and (vi) a back panel. The left side panel, the right side panel, the front panel, the bottom panel, the top member, and the back panel are configured to form the engraving chamber defined by the housing wherein the bottom panel is removable. When the bottom panel is removed, the laser processing system can be placed onto a workpiece that is larger than the engraving chamber. The laser processing system may further comprise one or more modular attachments for a specialized function wherein the laser processing system is stacked onto the modular attachment when the bottom panel is removed. For example, the laser processing system may further include a rotary attachment for engraving cylindrical surfaces. In other examples, the laser processing system may further include an automatic conveyor attachment, an automatic material handling stack attachment, and/or various subfloors configured for specialized applications and materials.

In an additional embodiment of the present invention, a non-telescoping focus mechanism for a laser processing system comprises: (a) a carriage mirror subassembly including (i) a carriage mirror and a carriage mirror mount wherein the carriage mirror subassembly is attached to a linear carriage of the laser processing system; (b) a sliding member that is moveably engaged with the linear carriage and includes (i) a linear guiding component (ii) a locking component; and (c) a focusing lens subassembly that is attached to a lower end of the sliding member and includes (i) a lens holder and (ii) a focus lens. The carriage mirror and the focus lens are configured to receive and focus a laser beam to a focal point. The focusing lens subassembly is adjusted to a vertical position by vertically sliding the sliding member and the focusing lens subassembly is locked into the vertical position by engaging the locking component with the sliding member. In an embodiment of the present invention, the linear carriage (to which the carriage mirror subassembly is attached) is the x-axis carriage of the laser processing system. In one version of the invention, the sliding member is a flat plate, the linear guiding component is comprised of at least one slot, and the locking component is a locking screw that engages with the sliding member by inserting the locking screw into the at least one slot. In some versions of this embodiment, the laser processing system includes a housing comprising a removable bottom panel.

In one embodiment of the invention, the sliding member is cylindrical, and the linear guiding component is comprised of (i) a first slot that allows the laser beam to enter the sliding member and to reflect off the carriage mirror, (ii) a second slot that provides clearance for the carriage mirror mount, and (iii) a third slot that provides clearance for the locking component. In another embodiment of the invention, the sliding member is a linear member comprising (i) a linear stage moveably mounted to the x-axis carriage and (ii) a linear member housing that surrounds the linear stage. Yet, in another embodiment of the invention, the sliding member includes a linear stage and a linear guiding component including one or more cylindrical motion guides, such as screws or rails, wherein the linear stage is guided along the vertical axis and is connected operatively to the focusing lens subassembly. In a further embodiment, the sliding member includes a motorized mechanism to automatically adjust the vertical position of the sliding member to thereby adjust the position of the focusing lens subassembly. For instance, the sliding member may include a powered vertical stage controlled by the engraving machine motion controller.

In a further embodiment of the present invention, a non-telescoping focus mechanism for a laser processing system comprises: (a) a carriage mirror subassembly including (i) a first lateral side attached to an x-axis carriage of the laser processing system and (ii) a second lateral side opposite the first lateral side wherein the second lateral side includes a lock aperture; (b) a sliding plate that is moveably attached to the second lateral side of the carriage mirror subassembly and includes (i) a locking component and (ii) a linear guiding component; and (c) a focusing lens subassembly attached perpendicularly to a lower end of the sliding plate wherein the carriage mirror subassembly and the focusing lens subassembly are configured to receive and focus a laser beam to a focal point. The focusing lens subassembly is adjusted to a vertical position by vertically sliding the sliding plate, and the focusing lens subassembly is locked into the vertical position by inserting the locking component into the lock aperture. The locking component may be comprised of a locking screw or any suitable locking mechanism known in the art. Also, the sliding plate is interchangeable with an alternate-length sliding plate (e.g., longer sliding plate).

In one embodiment of the invention, the linear guiding component comprises a center slot that runs longitudinally along the sliding plate wherein the locking component is moveably engaged with the center slot. In another embodiment, the linear guiding component further includes a first slot and a second slot that run parallel to the center slot wherein the center slot is positioned between the first slot and the second slot. The non-telescoping focus mechanism may further include a first locating pin and a second locating pin wherein the first locating pin and the second locating pin are attached to the second lateral side of the carriage mirror subassembly. The first slot slides over the first locating pin and the second slot slides over the second locating pin to maintain the focusing lens subassembly parallel to an engraving plane. In some versions of this embodiment, the laser processing system includes a housing comprising a removable bottom panel.

The above description sets forth a summary of embodiments of the present invention so that the detailed description that follows may be better understood and contributions of the present invention to the art may be better appreciated. Some of the embodiments of the present invention may not include all of the features or characteristics listed in the above summary. There may be, of course, other features of the invention that will be described below and may form the subject matter of claims. In this respect, before explaining at least one embodiment of the invention in further detail, it is to be understood that the invention is not limited in its application to the details of the construction and to the arrangement of the components set forth in the following description or as illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Furthermore, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

Other features, aspects, and advantages of the present invention will become apparent from the following description of the invention, taken in conjunction with the accompanying drawings, which illustrate, by way of example, various features of embodiments of the invention.

DESCRIPTION OF THE INVENTION

In the following description of embodiments of the invention, reference is made to the accompanying drawings, which form a part of this application. The drawings show, by way of illustration, certain embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and modifications may be made without departing from the scope of the present invention. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

For ease of reference, the following reference numbers are consistently used in the accompanying drawings of the present application to depict various components and embodiments of the present invention.

REFERENCE NUMBERS

Referring toFIGS. 1 and 2, the laser processing system apparatus is shown comprising a housing100defining an engraving chamber175that is accessed by a lid155and includes a removable bottom panel140. Operatively associated with the engraving chamber175is an xy laser beam steering system200, which is shown in more detail inFIG. 5. The laser processing system of the present invention therefore comprises: (a) housing100defining engraving chamber175, (b) xy laser beam steering system200located inside engraving chamber175, and (c) a focus mechanism that is moveably mounted onto x-axis carriage400of xy laser beam steering system200(see alsoFIGS. 5-6).

Housing and Exterior Components

FIGS. 1-3depict housing100in accordance with an embodiment of the present invention. As seen inFIGS. 1-3, the housing is comprised of: a left side panel110, a right side panel120, a front panel130, a bottom panel140(shown inFIG. 2), a top member150, and a back panel160. In the embodiment of the invention shown inFIGS. 1-3, the following pairs of frame members are positioned parallel to one another: (i) left side panel110and right side panel120, (ii) bottom panel140and top member150, and (iii) front panel130and back panel160. Left side panel110, right side panel120, front member130, bottom panel140, top member150, and back panel160are configured to form a rectangular prism-like shape wherein engraving chamber175is formed therein.FIGS. 1-2illustrate an embodiment of the invention wherein housing100includes an optional interior panel165that is parallel to back panel160. Interior panel165may function to cover and/or protect some of the optics and motion components of the present invention such as laser tube910and first mirror971shown inFIG. 3, which depicts the laser processing system of the present invention without interior panel165.

The panelized structure of housing100allows for the disengagement of one or more panels of housing100. As shown inFIG. 2, bottom panel140is removable in some embodiments of the invention. Bottom panel140disengages from left side panel110, right side panel120, front panel130, and back panel160. When bottom panel140is removed from housing100, the laser processing system can be placed onto a workpiece that exceeds the dimensions of engraving chamber175. Thus, when bottom panel140is removed, the laser processing system of the present invention can cut and engrave materials of any size and thickness. Additionally, the removability of bottom panel140allows the laser processing system of the present invention to accommodate a variety of modular attachments as discussed in the proceeding section.

In the embodiment shown inFIGS. 1-3, top member150includes lid155connected to top member150by a first hinge151and a second hinge152. As illustrated inFIG. 1, lid155may be comprised of a flat clear plastic for ease of viewing of the interior components of the laser processing system, and lid155does not need to be sealed when it is in the closed position. Top member150may also include a sloping surface157that runs horizontally along front panel130. A control panel808may be positioned on sloping surface157as the angled surface of sloping surface157permits ease of access and visibility of user control panel808. Control panel808may comprise of a LCD display and may include a power reporting capacitive touch interface wherein its front surface includes painted icons and a screen for data display. The icons correspond to an underlying PCB with pads designed to sense the presence of fingertips. Additionally, control panel808can provide reports regarding a variety of criteria such as the state of the laser, including the current driving the tube.

As shown inFIG. 3, a power switch802may be positioned on any suitable surface of housing100such as on top member150for immediate access and visibility. An exhaust outlet880is located on back panel160. A power connection804and a control card connection806may be positioned on right side panel120or on left side panel130in other versions of the invention.FIG. 3also illustrates a magnetic safety interlock switch860that deactivates the laser if lid155is opened during operation of the laser processing system.

Modular Attachments

The removability of bottom panel140from housing100as depicted inFIG. 2allows the present invention to accommodate a variety of modular attachments for enhanced capability and functionality. For instance, the laser processing system may further include one or more modular attachments to perform a specialized function that allows the present invention to process certain types, sizes, and/or shapes of materials. To use the modular attachment, bottom panel140is removed from housing100, and the laser processing system is then stacked onto the modular attachment, although some attachments do not require the removal of bottom panel140since these attachments are dimensioned and shaped to fit into engraving chamber175.

The stackable feature allows the present invention to be stacked on a variety of modular attachments of different kinds, sizes, and shapes since the modular attachment is not restricted to the dimensions and shape of engraving chamber175. These modular attachments provide enhanced functionality such as part pass-through, automatic conveyor, and part processing and engraving on cylindrical surfaces.

For example, the modular attachment may comprise of a rotary attachment for engraving cylindrical surfaces. The rotary attachment may be a friction-wheel type in which objects rest on two driven and two idling wheels, and the objects are turned to engrave an image onto the surface of the cylindrical object. Because some small objects are very light, the rotary attachment includes two hold-down plates to force light objects into contact with the drive wheel. The rotary attachment works by translating Y motion along a cylindrical surface (i.e., Y-axis motion is sent to the rotary). In some embodiments, the rotary attachment may be used inside engraving chamber175; however, removing bottom panel140can increase the maximum engraving diameter.

In other embodiments, bottom panel140can be removed so that the laser processing system can be placed on a frame to allow for thick part processing, a pass-through system, and other functions. The modular attachment may comprise of an automatic conveyor stack attachment or an automatic material handling stack attachment. Additionally, the modular attachment may comprise of one or more alternate subfloors that are specialized for a particular application and/or material, or bottom panel140may be interchangeable with alternate bottom panels that are configured and designed to perform specialized functions.

Optics and Motion Components

FIG. 4depicts a perspective view of some of optics and motion components of the laser processing system of the present invention. In one embodiment, the laser processing system may include: a laser tube910, a beam combiner915, diode laser and mount915, a first mirror971, and a second mirror972, which is mounted onto first y-axis carriage310. Beam combiner915(collimator) may be comprised of one piece with a pass-through mount comprising: a rear slot, a front counter bore aligned on the rear slot to allow a laser to pass through the center of the optic, two screws for mounting the optic element, and two mounting screws for mounting beam combiner915. Also included as part of the optics system of the present invention are a carriage mirror subassembly700and a focusing lens subassembly600which are both shown in more detail inFIGS. 6-9. Generally, laser tube910emits a laser beam that passes through beam combiner915, and the laser beam reflects off first mirror971, second mirror972, and carriage mirror773to direct the laser beam trough focusing lens650and ultimately onto the workpiece (seeFIGS. 8-9for depictions of carriage mirror773and focusing lens650).

The motion components of the present invention include y-axis motor260and y-axis driveshaft270which power the movement of the y-axis carriages of xy laser beam steering system200.

XY Laser Beam Steering System

FIG. 5illustrates the xy laser beam steering system200. The xy laser beam steering system200is comprised of a pair of y-axis carriages comprising a first y-axis carriage310and a second y-axis carriage320with a pair of y-axis rails comprised of a first y-axis rail210and a second y-axis rail220extending there between. An x-axis carriage400rides on x-axis rail250for axial movement along an x-axis along x-axis rail250.

Still referring toFIG. 5, xy laser beam steering system200therefore includes: (a) first y-axis rail210; (b) second y-axis rail220parallel to first y-axis rail210; (c) first y-axis carriage310moveably mounted to first y-axis rail210(to allow first y-axis carriage310to ride on first y-axis rail210); (d) second y-axis carriage320moveably mounted to second x-axis rail220(to allow second y-axis carriage320to ride on second y-axis rail220; (e) x-axis rail250that is perpendicular to both first y-axis rail210and second y-axis rail220wherein one end of x-axis rail250is adjoined to first y-axis carriage310and the other end of x-axis rail250is adjoined to second y-axis carriage320; and (f) x-axis carriage400moveably mounted to x-axis rail250(to allow x-axis carriage400to ride on x-axis rail250).FIG. 6depicts a closer view of first y-axis carriage310, which rides on first y-axis rail210and of x-axis carriage400, which rides on x-axis rail250. XY laser beam steering system essentially steers the laser head (i.e., x-axis carriage400) at a specific location on the surface of a workpiece to cut or engrave the workpiece.

Sliding Focusing Mechanism

As shown inFIG. 6, the sliding, non-telescoping focus mechanism of the present invention resides on x-axis carriage400. The focusing mechanism comprises: (a) a carriage mirror subassembly700attached to x-axis carriage400, (b) a sliding member500including a linear guiding component and a locking component555wherein sliding member500is moveably attached to carriage mirror subassembly700, and (c) a focusing lens subassembly600attached to a lower end of sliding member500.

As shown inFIG. 7, carriage mirror subassembly700and focusing lens subassembly600are configured to receive and focus a laser beam25to a focal point95. Focusing lens subassembly600is adjusted along the z-axis of engraving chamber175by disengaging locking component555and vertically sliding member500, which is sometimes referred to herein as an actuating arm. When sliding member500is slid vertically, sliding member does not telescope with another member when adjusting the position of focusing lens subassembly600along the z-axis. In other words, sliding member500is not inserted into another enclosed member, nor is another member inserted inside sliding member500to adjust the position of focusing lens subassembly600along the z-axis. Sliding member is comprised of one or more exposed members that are not covered, enclosed or telescoped by another member to adjust focusing lens subassembly600as in other mechanisms used by other laser processing systems. Therefore, the non-telescoping focusing mechanism of the present invention is not limited in vertical distance and movement as in mechanisms that utilize telescoping members, which are limited to the shortest vertical length of the telescoping members.

The x-axis carriage400is depicted inFIG. 7and carries carriage mirror subassembly700optically coupled to focusing lens subassembly600. Carriage mirror subassembly700and focusing lens subassembly600are configured to receive and focus a laser beam25to a focal point95. In the embodiment shown inFIGS. 6-9, sliding member500is comprised of a flat plate including a first mounting pin591and a second mounting pin592for focusing lens subassembly600. Focusing lens subassembly600is mounted to sliding member500via first mounting pin591and second mounting pin592.

The linear guide component of the sliding member may include one or more slots, pins, screws and/or rails or any another suitable mechanism that linearly guides the sliding member's vertical motion and helps secure the sliding member into a vertical position. For example, as shown inFIG. 7, Sliding member500includes a linear guiding component comprised of a first slot511, a second slot512, and a center slot515in between first slot511and second slot512. First slot511and second slot512are in operative association with a first locating pin521and a second locating pin522, respectively; and center slot515is in operative association with a locking component555. Thus, first slot511, second slot512, center slot515, first locating pin521, second locating pin522, and locking component555all work together to help linearly guide the vertical movement of sliding member500.

As shown inFIG. 7, first slot511, second slot512, and center slot515are configured so that the focusing lens subassembly600is able to move along the z-axis of engraving chamber175when locking component555is loosened. This design allows the top of sliding member500to move above the path of laser beam25that is traveling directly into carriage mirror subassembly700. First slot511and second slot512slide over first locating pin521and second locating pin522, respectively, which force the sliding member500to maintain focusing lens subassembly600parallel to an engraving plane45when locking component555is tightened. The removal of bottom panel140(seeFIG. 2) allows engraving plane45to be moved outside of the normal bounds of engraving chamber175and onto workpieces located below housing100. When sliding mechanism500is fully retracted, it utilizes the space between the top of the xy beam steering system200and lid155, therefore expanding the capabilities of the present invention while also maintaining compactness.

Still referring toFIG. 7, x-axis carriage400includes a mounting plate430to which carriage mirror subassembly700is attached. X-carriage400is engaged with x-axis rail250and travels along x-axis rail250via a plurality of rollers comprising: a first roller481, a second roller482, a third roller483, and a fourth roller484(not shown inFIG. 7), which engage x-axis carriage400with a guide channel located on x-axis rail250to move x-axis carriage400horizontally within engraving chamber175. First roller481and second roller482are fixed rollers, whereas third roller483and fourth roller484are eccentric rollers that can be adjusted during the roller/wheel alignment of x-axis carriage400onto x-axis rail250. On the opposite side of mounting plate430, x-axis carriage400further includes: a first nut491securing first roller481, a second nut492securing second roller482, a first eccentric nut493securing third roller483, and a second eccentric nut494securing fourth roller484. When aligning x-axis carriage400onto x-axis rail250, first eccentric nut493and second eccentric nut494can be loosened or tightened to adjust third roller483and fourth roller484, respectively. First eccentric nut493and second eccentric nut494allows for variable friction between third roller483and fourth roller484, respectively, allow for adjustment and alignment of x-axis carriage400.

FIG. 7depicts x-axis carriage400wherein sliding member500is at its highest position (i.e., focusing lens subassembly600is at its closest possible position to carriage mirror subassembly700).FIG. 8depicts x-axis carriage400with sliding member500slightly lowered from its highest position shown inFIG. 7.FIG. 9depicts x-axis carriage400with sliding member500at its lowest position (i.e., focusing lens subassembly600is at its furthest possible position from carriage mirror subassembly700). As seen inFIGS. 8-9, carriage mirror subassembly700includes carriage mirror mount710, a carriage mirror holder739, and a carriage mirror773. Carriage mirror mount710includes an aperture through which locking component555is inserted to secure sliding member500in place. Focusing lens subassembly600includes a lens holder610and a focus lens650. Lens holder610can be interchanged with other designs to allow for different focal length lenses. A quick-change focusing lens subassembly600allows variable thickness/focal length lenses. Also, an air assist attachment980is attached to the rear of focusing lens subassembly600as illustrated inFIGS. 8-9, and air assist attachment980comprises a bulkhead mount air coupler for collimated debris removable. Although an air assist attachment can function with multiple lenses, different air assist attachments are possible for extra thick/thin lenses.

As depicted in the embodiment shown inFIGS. 6-9, sliding member500includes a linear guiding component including first slot511positioned on an outer edge of sliding member500, second slot512positioned on the opposite outer edge on which511is located, and a center slot515of elliptical profile, but other profiles and numbers of slots may be suitable as well in alternate embodiments of the invention. For example, in other embodiments of the invention, sliding member500may include a linear guiding component comprising one slot, two slots, four slots, five slots, or six slots. In an alternate embodiment, the linear guiding component may include pins, screws and/or rails or any another suitable mechanism that linearly guides the sliding member's vertical motion. For instance, linear guiding component may include a vertical rail to which sliding member500is moveably attached to allow sliding member500to travel vertically on the vertical rail. Sliding member500may be attached directly to the vertical rail, or it may be attached to an intermediary structure such as a mounting plate that is moveably attached to and engages directly with the vertical rail. In another embodiment, linear guiding component may be comprised of a stage and a vertical rail wherein the stage moves vertically and the vertical rail remains fixed; or in alternative versions, the stage remains fixed and the vertical rail travels vertically. In an additional embodiment of the invention, sliding member500includes a linear stage and a linear guiding component including one or more cylindrical motion guides, such as screws or rails, wherein the linear stage is guided along the vertical axis and is connected operatively to focusing lens subassembly600. Yet, in a further embodiment, sliding member500includes a motorized mechanism to automatically adjust the vertical position of sliding member500to thereby adjust the position of the focusing lens subassembly600. For example, sliding member500may include a powered vertical stage controlled by the engraving machine motion controller.

In varying embodiments of the invention, sliding member500may be moveably engaged to carriage mirror subassembly700or moveably engaged to a linear carriage (e.g., x-axis carriage400), and the linear guiding component may be attached to carriage mirror subassembly700and/or to a linear carriage (e.g., x-axis carriage400).

Also,FIGS. 6-9depict an embodiment of the invention in which locking component555is comprised of a locking screw. However, other locking mechanisms are possible such as those comprising a retaining pin, male/female structure that include one or more screws, pins, snaps, clips, and other complementary engaging members, and any other suitable locking mechanisms known in the art. Additionally, sliding member500may be comprised of other shapes, sizes, and configurations (e.g., sliding member500may be elliptical instead of rectangular, cylindrical, linear, etc.). Furthermore, sliding member500is interchangeable with alternate-sized sliding members. For instance, a longer sliding member can be used with the present invention to provide longer distances between focusing lens subassembly600and carriage mirror subassembly700and/or to allow focusing lens subassembly600to get closer to a particular workpiece.

Another embodiment of the focusing mechanism of the present invention is shown inFIGS. 10-11, and depicts carriage mirror subassembly700optically coupled to focusing lens subassembly600.FIG. 10depicts sliding member500in a low position such that focusing lens subassembly600is at a distance from carriage mirror subassembly700, andFIG. 11depicts sliding member500in its highest position such that focusing lens subassembly600is closest to carriage mirror subassembly700. Carriage mirror subassembly700and focusing lens subassembly600are configured to receive and focus a laser beam25to a focal point95. In this embodiment of the invention, the actuating arm/sliding member500is cylindrical and mounted to focusing lens subassembly600. Sliding member500is fixed in space when locking component555is engaged with sliding member500. Sliding member500is comprised of a cylinder including three slots: one slot to allow laser beam25to enter the interior and reflect off of carriage mirror subassembly700, a second slot to provide clearance for carriage mirror subassembly mount710, and a third slot to provide clearance for locking component555. The bottom of the cylindrical sliding member500is open and may be threaded to mate with focusing lens subassembly600. This configuration also allows part of sliding member500to pass above laser beam25. Also depicted inFIGS. 10-11are first roller481and second roller482attached to mounting plate430, which includes a depression435adapted to receive cylindrical sliding member500as it is moved vertically upward and downward to adjust the position of focusing lens subassembly600along the z-axis.

A further embodiment of the focusing mechanism of the present invention is shown inFIGS. 12-13, and depicts carriage mirror subassembly700optically coupled to focusing lens subassembly600.FIG. 12depicts sliding member500in a low position such that focusing lens subassembly600is at a distance from carriage mirror subassembly700, andFIG. 13depicts sliding member500at a higher position such that focusing lens subassembly600is closer to carriage mirror subassembly700than as depicted inFIG. 12. Carriage mirror subassembly700and focusing lens subassembly600are configured to receive and focus a laser beam25to focal point95. In this embodiment, actuating arm/sliding member500is a linear slider subassembly mounted to focusing lens subassembly600. Focusing lens subassembly600is fixed in space when locking component555is engaged to sliding member500. The linear slider/sliding member500is comprised of a linear stage580mounted to x-axis carriage400and contained in a linear member housing570which itself is mounted to focus lens subassembly600. This configuration also allows part of the actuating arm/sliding member500to pass above laser beam25. Also shown inFIGS. 12-13are first roller481, second roller482, and third roller483attached to mounting plate430. In the embodiment of the invention depicted inFIGS. 12-13, sliding member500is not attached to carriage mirror subassembly700as in the embodiment illustrated inFIGS. 6-9. Rather, sliding member500is moveably mounted onto mounting plate430to allow sliding member500to vertically travel upward and downward to adjust the position of focusing lens subassembly600along the z-axis.

As shown in the embodiments of the invention depicted inFIGS. 7-13, carriage mirror subassembly700and focusing lens subassembly600are configured to receive and focus laser beam25to focal point95wherein focus lens650of focusing lens subassembly600is perpendicular to laser beam25. Lens holder610may be comprised of any shape, and in embodiments of the invention wherein carriage mirror773is comprised of an articulated mirror, then focus lens650would rotate with carriage mirror773to maintain perpendicularity to laser beam25.

EXAMPLES

In the foregoing description of embodiments of the invention, reference was made to the accompanying figures, which form a part of this application. The figures show, by way of illustration, certain embodiments in which the invention may be practiced. It is to be understood that other variations are possible and modifications may be made without departing from the scope of the present invention. A variety of embodiments are possible wherein each embodiment includes a different combination of the different aspects and elements of the present invention.

For example, in one embodiment as shown inFIGS. 1-9, a laser processing system is comprised of: (a) housing100defining engraving chamber175, (b) xy laser beam steering system200located inside engraving chamber175, and (c) a non-telescoping focus mechanism. As shown inFIG. 5, xy laser beam steering system200includes: (i) first y-axis rail210, (ii) second y-axis rail220parallel to first y-axis rail210, (iii) first y-axis carriage310moveably mounted to first y-axis rail210, (iv) second y-axis carriage320moveably mounted to second x-axis rail220, (v) x-axis rail250perpendicular to both first y-axis rail310and second y-axis rail320wherein one end of x-axis rail250is adjoined to first y-axis carriage310and the other end of x-axis rail250is adjoined to second y-axis carriage320, and (vi) x-axis carriage400moveably mounted to x-axis rail250. As depicted inFIGS. 7-11, non-telescoping focus mechanism comprises: (i) carriage mirror subassembly700attached to x-axis carriage400, (ii) sliding member500which includes a linear guiding component and a locking component555wherein sliding member500is moveably attached to carriage mirror subassembly700, and (iii) focusing lens subassembly600attached to a lower end of sliding member500. Carriage mirror subassembly700and focusing lens subassembly600are configured to receive and focus a laser beam25to focal point95. Focusing lens subassembly600is adjusted along the z-axis of engraving chamber175by disengaging locking component555and vertically moving sliding member500.

In the embodiment of the invention shown inFIG. 7, sliding member500is comprised of a flat plate and the a linear guiding component is comprised of first slot511, second slot512, and center slot515wherein locking component555is engaged with center slot515to hold focusing lens subassembly600at a position along the z-axis. As depicted inFIGS. 8-9, focusing lens subassembly600includes focus lens650and lens holder610, which is interchangeable to allow for different focal length lenses. X-axis carriage400comprises a plurality of rollers that move x-axis carriage400along x-axis rail250. As shown inFIG. 7, the plurality of rollers comprises (i) first roller481(first fixed roller), (ii) second roller482(second fixed roller), (iii) third roller483(first eccentric roller), and (iv) fourth roller484(second eccentric roller) wherein third roller483and fourth roller484can each be adjusted to align x-axis carriage400along x-axis rail250.

In the foregoing example and as shown inFIGS. 1-3, housing100may be comprised of: (i) left side panel110, (ii) right side panel120, (iii) front panel130, (iv) bottom panel140, (v) top member150, and (vi) back panel160. The aforementioned panels are configured to form engraving chamber175defined by housing100. In some versions of the invention, bottom panel140is removable as illustrated inFIG. 2. When bottom panel140is removed, the laser processing system of the present invention can be placed onto a workpiece that is larger than the engraving chamber. The laser processing system may further comprise one or more modular attachments for a specialized function wherein the laser processing system is stacked onto the modular attachment when bottom panel150is removed. For example, the laser processing system may further include a rotary attachment for engraving cylindrical surfaces. In another example, the laser processing system may further include an automatic conveyor attachment and/or an automatic material handling stack attachment.

In another example, an alternate embodiment of the invention is directed to a non-telescoping focus mechanism for a laser processing system as depicted inFIGS. 6-13. The non-telescoping focus mechanism is comprised of: (a) carriage mirror subassembly700including carriage mirror773and carriage mirror mount710wherein carriage mirror subassembly700is attached to a linear carriage such as x-axis carriage400of the laser processing system; (b) sliding member500that is moveably engaged with x-axis carriage400and includes a linear guiding component and locking component555; and (c) focusing lens subassembly600that is attached perpendicularly to a lower end of sliding member500and includes lens holder610and focus lens650. Carriage mirror773and focus lens650are configured to receive and focus laser beam25to a focal point95. Focusing lens subassembly600is adjusted to a vertical position by vertically sliding the sliding member500and focusing lens subassembly600is locked into the vertical position by engaging locking component555with sliding member500. In one version of the invention as shown inFIGS. 6-9, sliding member500is a flat plate, the linear guiding component includes at least one slot, and locking component555is a locking screw that engages with sliding member500by inserting the locking screw555into the at least one slot. In some versions of this embodiment, the laser processing system includes a housing100comprising removable bottom panel140(seeFIG. 2).

In one embodiment of the foregoing example, the sliding member is cylindrical as illustrated inFIGS. 10-11. In this embodiment, the linear guiding component is comprised of (i) a first slot that allows laser beam25to enter sliding member500and to reflect off the carriage mirror773, (ii) a second slot that provides clearance for the carriage mirror mount773, and (iii) a third slot that provides clearance for locking component555. Carriage mirror773and carriage mirror mount773are not shown inFIGS. 10-11since they reside inside of sliding member500. Yet, in another embodiment of the invention as illustrated inFIGS. 12-13, sliding member500is a linear member comprising of (i) linear stage580moveably mounted to x-axis carriage400and (ii) linear member housing570that surrounds linear stage580. In an additional embodiment, the linear guiding component is comprised of a vertical rail and sliding member500is moveably attached to the vertical rail to allow sliding member500to travel vertically. Sliding member500may include a motorized mechanism to vertically move sliding member500(e.g., sliding member500may include a powered vertical stage controlled by the engraving machine motion controller).

In a further example, a non-telescoping focus mechanism for a laser processing system is depicted inFIGS. 6-9and is comprised of: (a) carriage mirror subassembly700including (i) a first lateral side attached to x-axis carriage400and (ii) a second lateral side opposite the first lateral side wherein the second lateral side includes lock aperture; (b) sliding plate500that is moveably attached to the second lateral side of carriage mirror subassembly700and includes (i) locking component555and (ii) a linear guiding component; and (c) focusing lens subassembly600attached perpendicularly to a lower end of sliding plate500wherein carriage mirror subassembly700and focusing lens subassembly600are configured to receive and focus a laser beam25to a focal point95(seeFIG. 7). Focusing lens subassembly600is adjusted to a vertical position by vertically sliding the sliding plate500, and focusing lens subassembly600is locked into the vertical position by inserting locking component555into the lock aperture on the carriage mirror subassembly700. Locking component555may be comprised of a locking screw or any suitable locking mechanism known in the art. Also, sliding plate500is interchangeable with an alternate-length sliding plate (e.g., longer sliding plate) to provide varying focal lengths.

In one embodiment of the foregoing example as shown inFIG. 7, the linear guiding component includes a center slot515that runs longitudinally along sliding plate500, a first slot511, and second slot512that run parallel to center slot515. Locking component555is moveably engaged with center slot515. Center slot515is positioned between first slot511and second slot512. The non-telescoping focus mechanism may further include first locating pin521and second locating pin522that are attached to the second lateral side of carriage mirror subassembly700. First slot511slides over first locating pin521and second slot512slides over second locating pin511to maintain focusing lens subassembly600parallel to engraving plane45. In some versions of this embodiment, the laser processing system includes a housing100comprising a removable bottom panel140(seeFIG. 2).

Although the present invention has been described above in considerable detail with reference to certain versions thereof, other versions are possible. Many of the elements of the invention may be of alternate suitable shapes, sizes, and/or configurations; may further include structures not described hereinabove; may exclude one or more components described above, and may be positioned at alternate suitable locations within the apparatus without departing from the spirit and scope of the present invention.

The attached figures depicting various embodiments of the invention are primarily intended to convey the basic principles embodied in the present invention. Thus, the present invention may further include additional structures and features not illustrated in the figures. Also, various structures of the present invention such as the dimensions, shapes, and configuration of the interchangeable components and modular attachments may be customized to accommodate a particular size, shape and/or type of material.

While the description above refers to particular embodiments of the present invention, it will be understood that many modifications may be made without departing from the spirit thereof. The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive.