Patent ID: 12228908

DETAILED DESCRIPTION

As stated herein, the objective of the present disclosure is to provide an apparatus, system and methods for cutting material using a Computer Numeric Control (CNC) process to create images in the surface of the material by removing varying size sections or slices of material from the surface. In particular, the objective of the present disclosure also relates to an apparatus, system and methods in which a knife or cutting tool controlled by a CNC machine is used to cut away or remove slices of felt or PET material, using guide curves, different cutting angles, depths and range of motion, to generate different intensities, from the surface of the sheet of material, thereby leaving an image in the remaining surface area.

Referring to the drawings, wherein like reference numerals refer to the same or similar features in the various views,FIGS.1through6show different views of the improved CNC cutting system10.

FIG.1shows a functional block diagram of the system10, including the original or source image12, the scanning device14for scanning the original or source image into the system10. Of course, as understood by one having ordinary skill in the art, other ways exist of inputting or entering an original image into a computer16, or a database18coupled to or connected to the computer16. Once the original image12is scanned, captured, or otherwise inputted, a computer program20can convert the original or source image12through pixilation, rasterization or other methods, to create a computer image file22associated with the original image12. As described in detail herein, the computer image file22incorporates or is made up of guide curves which will be used to control the cutting of the material.

Once the computer image file22is generated, a controller24uses the information to control a CNC cutting machine26, as understood by one having ordinary skill in the art, to cut, slice or indent the surface28of the material30, to replicate the original image12onto the surface28of the material30.

FIG.2shows the CNC cutting machine26that includes a cutting or slicing element32used to cut the surface28of the material30. As understood, the CNC cutting machine26, and in particular, the cutting element32can be moved in three dimensions X, Y and Z to effect cuts or slices in the material30in three dimensional space. A number of different cutting elements or devices32can be used to accomplish the same cutting or slicing effect, including lasers, milling machines and/or drilling devices.

FIG.3shows a system flowchart for the cutting system10. The program starts at step40and proceeds to initiate and utilize a scanning device14to scan in the original image12at step42. If the original or source image12is a virtual or digital image, there is no need to scan the source image12and the process can begin at step44.

Once scanned and/or saved into the database18, step44uses the computer program20(stored in the database18) to access the scanned original image12(also stored in the database18) and converts the original image12to a computer image file22. As described herein, the conversion includes any of a number of processes, but takes into account the intensities and/or colors of the original image12to generate the computer image file22. This is important since depending on the intensities of the scanned original image12, different ranges of motion, angles and depths (collectively guide curves) from the computer image file22will be used to control the CNC cutting machine26to remove slices from the surface28of the material30to replicate the original image12.

Once converted, the computer image file22is stored in the database20at step46, where, at step48it can be accessed by the computer program18for further processing. Next, at step50, the system10and the computer program18will utilize CAD, CAM and/or CNC software to further process the computer image file22in order for final material cutting.

Once the computer image file22is ready at step52, the program18accesses the controller24and instructs the controller24to control the CNC cutting machine26. At step54, the controller24controls the CNC cutting machine26to cut, slice or indent the surface28of the material30, based on the guide curves in the computer image file, thereby creating the replicated image on the surface28of the material30. The system process ends at step56.

Although the process is described with various steps in a particular order, one having ordinary skill in the art would understand that these steps can be combined and/or further expanded without diverging from the scope of the disclosure described herein. Additionally, the order of the steps can be changed or modified, and additionally or alternatively, multiple databases or computer programs can be implemented with the same result.

The program(s) and database(s) can be located and accessed locally and/or remotely with the same results. For example, the program for converting the original image12to the computer image file22(step44) can be located remotely, while the program or portion of the program for controlling the CNC machine (step52) can be located locally on a local computer (or vice-versa). Another example includes a scanning device located remotely from the CNC cutting machine such that the original image12can be scanned remotely and the actual cutting (Step54) can be done locally (or vice-versa). Of course, many other options exist all falling under the rubric of the disclosure herein.

FIG.4shows a side view of three 45 degree bevel cuts, the first 45 degree bevel cut60, the second 45 degree bevel cut62, and the third 45 degree bevel cut64. The first 45 degree bevel cut60shows a control line66and a variable line68. The control line66stays constant from a first end70(FIG.5) of the surface28of the material30to a second end72(FIG.5) of the surface28of the material30. The variable line68deviates from the control line66based on the guide curve generated in the computer image file22. The range of motion74is a function of the distance or deviation that the variable line68will move from and to the control line66.

More or less of the shaded area76will be cut away depending on the deviation of the variable line68from the control line66. The second 45 degree bevel cut62shows a smaller deviation between the control line66and the variable line68resulting in a smaller slice78(FIG.5) and a minimum removal. The third 45 degree bevel cut64shows a larger deviation between the control line66and the variable line68resulting in a larger slice78(FIG.5) and a maximum removal.

FIG.5shows a perspective view of a single continuous 45 degree bevel cut80, using the control line66and the variable line68. The control line66stays constant from the first end70of the surface28of the material30to a second end72of the surface28of the material30. The changing deviation of the variable line68from further82to closer84to the control line66, changes the amount of the slice78to be removed.

FIG.6shows a top view of a multiple continuous 45 degree bevel cuts80, using the control line66and the variable line68. The control line66stays constant from the first end70of the surface28of the material30to a second end72of the surface28of the material30. The changing deviation of the variable line68from further82to closer84to the control line66, changes the amount of the slice78to be removed (FIG.7A).

FIGS.7A and7Bshow perspective views of a multiple continuous 45 degree bevel cuts80. The control line66stays constant from the first end70of the surface28of the material30to a second end72of the surface28of the material30. The changing deviation of the variable line68from further82to closer84to the control line66, changes the amount of the slice78to be removed.FIG.7Ashows the cut slice78being removed from the surface28or the material30.FIG.7Bshows the resultant image86with areas of greater intensity88, where the variable line68had maximum deviation from the control line66. The resultant image86also shows area of lesser intensity90, where the variable line68had minimal deviation from the control line66.

FIGS.8A and8Bshow alternative embodiments of the present disclosure.FIGS.8A and8Bshow the top and side views of the present disclosure including the various angles, depths and range of motions74of the cuttings on the surface28of the material30that allow for the different intensities depending on the original image12.

FIG.8Ashows a first dual 30 degree cut92, a second dual 30 degree cut94, and a third dual 30 degree cut96, at different heights that generate narrow92,94and broad96cuts and a relatively lower92,94and greater96intensity images. At 30 degrees, the first cut92will show a less intense view than the third cut96.

FIG.8B, on the other hand, shows a first dual 45 degree cut98, a second dual 45 degree cut100, and a third dual 45 degree cut102, at different heights that generate narrow98,100and broad102cuts and a relatively lower98,100and greater102intensity images. At 45 degrees, the first cut98will show a less intense view than the third cut102.

FIGS.9A and9Bshow the resultant image on the surface28of the material30.FIG.9Ashows a resultant image104after CNC cutting of the surface28of the material30.FIG.9Bshows a close up ofFIG.5A. As shown, the wider angle cuts106have a greater intensity and show more color than the cuts having a narrower angle108.

Similarly,FIGS.10A and10Bshow the resultant image of a face of a person on the surface28of the material30.FIG.10Ashows a resultant image110after CNC cutting of the surface28of the material30.FIG.10Bshows a close up ofFIG.10A. As shown, the wider angle cuts112have a greater intensity and show more color than the cuts having a narrower angle114.

As described herein, the material used in the preferred embodiment is polyester felt and is between 60% and 99% recycled material. Maintenance includes occasional vacuuming to remove particulate matter and air-borne debris or dust. Compressed air can be used to dust off the material in difficult to reach areas and for large assemblies.

The felt comes in numerous colors, including white, cream, light grey, light brown, brown, matte grey, charcoal, black, yellow, mango, orange, red, lavender, lime, green, light blue and dark blue, and can be manufactured in many other colors and the present disclosure is not limited to these specifications and colors, as these are merely the specifications and colors for the preferred embodiments and alternative embodiments.

Reference throughout the specification to “various embodiments,” “some embodiments,” “one embodiment,” or “an embodiment”, or the like, means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “in some embodiments,” “in one embodiment,” or “in an embodiment”, or the like, in places throughout the specification are not necessarily all referring to the same embodiment.

Further, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, the particular features, structures, or characteristics illustrated or described in connection with one embodiment may be combined, in whole or in part, with the features structures, or characteristics of one or more other embodiments without limitation given that such combination is not illogical or non-functional. Although numerous embodiments of this invention have been described above with a certain degree of particularity, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of this disclosure.

All directional references (e.g., plus, minus, upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of the any aspect of the disclosure.

As used herein, the phrased “configured to,” “configured for,” and similar phrases indicate that the subject device, apparatus, or system is designed and/or constructed (e.g., through appropriate hardware, software, and/or components) to fulfill one or more specific object purposes, not that the subject device, apparatus, or system is merely capable of performing the object purpose. Joinder references (e.g., attached, coupled, connected, and the like) are to be construed broadly and may include intermediate members between a connection of elements and relative movement between elements. As such, joinder references do not necessarily infer that two elements are directly connected and in fixed relation to each other. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure may be made without departing from the spirit of the invention as defined in the appended claims.

Any patent, publication, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated materials does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.