Preventing damage to laser engraver substrate transport mechanism

Abstract

A laser engraving system may include a transport mechanism (100) to position an engraving target relative to a laser source (118). The transport mechanism may include a belt (104) to move the engraving target, a drive roller (106) to drive the belt, and a safe zone configured to protect at least a portion of the belt from the beam of laser energy. The safe zone may include a protection member configured to be positioned below the laser source such that at least a portion of the protection member is located between the laser source and the belt. Additionally, or alternatively, a portion of the engraving target (e.g., a transparent area of the engraving target) may be cantilevered over an edge of the transport mechanism and energy from the laser source may be directed to the portion of the engraving target over the edge of the transport mechanism.

Description

PREVENTING DAMAGE TO LASER ENGRAVER SUBSTRATE TRANSPORT MECHANISMPRIORITY APPLICATION

[0001] This application claims priority to U. S. Provisional Patent Application Serial Number 63 / 579,409, filed on August 29, 2023, the disclosure of which is incorporated by reference herein in its entirety.TECHNICAL FIELD

[0002] The present disclosure relates to preventing damage to the transport mechanism of a laser engraving machine, specifically, when laser engraving transparent windows in, for example, a substrate such as a card being transported by the transport mechanism.BACKGROUND

[0003] Laser engravers are used to etch or engrave patterns on the surface of objects or substrates. The objects to be engraved may include cards, such as identification cards (e.g., government-issued licenses, workplace identification cards, or the like) or credit cards. Some cards have an optically transparent area or portion (e.g., a transparent window) made from transparent polycarbonate (PC), or the like, upon which an image, a pattern, wording, etc. may be engraved.SUMMARY

[0004] Described herein are systems and methods for preventing damage to a substrate transport mechanism of a laser engraving machine. A laser engraving system may generally include a laser source to emit a beam of laser energy or radiation toward an engraving target and a transport mechanism to position the engraving target relative to the laser source. The transport mechanism may include a belt to move the engraving target, a drive roller to drive the belt, and a plurality of idle rollers, sprockets, or the like to increase wrap of the belt around the drive roller. The laser engraving system may further include a protection member located below the laser source and configured to protect at least a portion of the belt from the beam of laser energy.

[0005] A method for protecting a transport mechanism of a laser engraver may include providing an engraving target on a transport mechanism of a laser engraver, the transportmechanism including a belt to move and / or position the engraving target. The method may also include positioning the engraving target relative to a fixed laser source using the transport mechanism. Positioning the engraving target may include locating an at least partially transparent area or an at least partially transparent portion (e.g., a transparent window) above a portion of the transport mechanism where the belt is protected from the laser energy (such as a portion of the transport mechanism where the belt is diverted below a protection member). It is understood that the terms transparent area, transparent portion, and transparent window may be used interchangeably throughout the present disclosure and refer to an at least partially transparent or semi-transparent portion of an engraving target. The method may also include engraving at least a portion of the at least partially transparent area using the fixed laser source.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] In the drawings, which are not necessarily drawn to scale, like numerals may describe similar components in different views. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.

[0007] FIG. 1 illustrates an example of a cross section of a laser engraver transport mechanism.

[0008] FIG. 2A illustrates an example of a cross section of a laser engraver transport mechanism.

[0009] FIGS. 2B-2C illustrate an example of a view from above the laser engraver transport mechanism of FIG. 2 A.

[0010] FIG. 2D illustrates an example of a view from above the laser engraver transport mechanism of FIG. 2A illustrating a material plate included in a protection member.

[0011] FIG. 3 illustrates an example side view of a two-belt transport mechanism of a laser engraver.

[0012] FIG. 4 illustrates an example of a method for protecting a transport mechanism of a laser engraver.DETAILED DESCRIPTION

[0013] Laser engravers use a transport mechanism to position cards to be engraved. The transport mechanism uses a belt to move and position an engraving target or substrate, such as a card, such as an identification card, a credit card, or the like, relative to a laser source or a source of infrared radiation. At least a portion of the engraving target or substrate may be optically transparent or semi-transparent. These transparent portions, areas, or windows may be engraved with an image or pattern by directing laser energy from the laser source to the surface of the engraving target or substrate. The surface of the engraving target or substrate, including the transparent portion, absorbs energy from the laser source causing the engraved image or pattern to appear on the engraving target or substrate.

[0014] Depending on the formulation of the window (e.g., polycarbonate), some of the laser energy may be transmitted through the transparent portion and may damage the belt. For example, the laser energy may cause the belt to heat up and partially melt. The melted surface of the belt may adhere to the surface of the engraving target or substrate that is in contact with the belt, causing a defect on the engraving target or substrate and resulting in the engraving target or substrate being thrown away. Additionally, the life of the belt damaged from laser energy may be reduced requiring the belt to be replaced more frequently. Furthermore, an image or a portion of an image or pattern, which may be proprietary to a customer or client whose engraving targets or substrates are being engraved, may be engraved on the belt causing a security or privacy issue.

[0015] Disclosed are systems and methods for protecting a transport mechanism for a laser engraver. The disclosed systems and methods make use of “safe zones” over which the transparent window on an engraving target or substrate may be positioned that are not occupied by the belt or at which the belt is blocked. Thus, during the engraving process, the laser energy may be used to engrave the transparent window without contacting the belt. Therefore, the belt remains protected during the engraving process, which in turn may prolong the useful life of the belt and reduce the likelihood that the engraving target or substrate being engraved will be damaged and need to be discarded.

[0016] FIG. 1 illustrates an example of a cross section of a laser engraver transport mechanism 100. The laser engraver transport mechanism 100 may be configured to move and position an engraving target 102 relative to a laser source 118. The laser engraver transport mechanism 100 may include a belt 104, a drive roller 106, and a number of idle rollers 108, 110, 112. The engraving target 102 may be positioned relative to laser source 118 along thebelt 104 as the belt 104 is driven by the drive roller 106. The drive roller 106 may include an internal motor and / or be powered by a battery or other power source to cause the drive roller to rotate, which in turn may cause the belt 104 to move. The idle rollers 108, 110, 112 may turn as the belt 104 is driven by the drive roller 106 and may increase the wrap of the belt 104 around the drive roller 106. The idle rollers 108, 110, 112 may thus provide extra drag on the belt 104 and reduce the amount of slip the belt 104 may experience when being driven by the drive roller 106.

[0017] A fan duct 122 may be located below the protection member that may be used to maintain positive engagement between the engraving target and the protection member and / or the belt during the engraving process. A surface of the fan duct (e.g., a top surface) may include a securing member, which may be a hole, groove, slot, or the like that may align with one or more holes in the belt 104. When the fan is active, a vacuum force may be created. The vacuum force may be communicated between the top of the fan duct 122 and the belt 104 through the slot in the fan duct 122 and the holes in the belt 104, which can keep the engraving target 102 secure on the belt 104 during the engraving process.

[0018] Thus, the securing member on the fan duct 122 may allow for a connection between the belt 104 and the fan duct to be maintained. For example, when the belt passes over the surface of the fan duct 122 (e.g., the top surface) a vacuum force may be created between the securing member and the belt 104. When the engraving target 102 blocks the holes in the belt 104, the vacuum force may secure the engraving target 102 to the belt 104 while the belt 104 moves and may help prevent the engraving target 102 from moving (e.g., slipping) on the belt 104 as the belt is driven by the drive roller 106 and / or during engraving.

[0019] Cantilevering The Engraving Target or Substrate Over an Edge of the Transport Mechanism:

[0020] An engraving target (e.g., a card) may be positioned so that a transparent portion is positioned away from the belt by cantilevering a portion of the engraving target or substrate over an edge of the transport mechanism (e.g., over the edge of the belt path or a path taken by the belt as the belt is in motion). Then, when energy is emitted from the laser source to engrave the transparent portion of the engraving target, any energy that is not absorbed by the transparent portion will not contact the belt. In an example, the laser source may be positioned above the safe zone (e.g., where the engraving target or substrate is cantilevered) or may be positioned elsewhere as appropriate or desired. In another example, the laser source may be movable, such as on a gantry, to allow the laser source to be positioned at different locations over the belt.

[0021] Thus, returning to FIG. 1, the fan duct 122 may be shaped and configured to, while the vacuum source 116 is in operation, create a vacuum force to keep the engraving target 102 secure on the belt 104 while it is cantilevered over an edge of the transport mechanism during the engraving process. A portion of the engraving target 102 may be positioned so that it hangs or is cantilevered over an edge of a path of the belt 104 (the belt path) such as at or near a portion of the transport mechanism where the engraving target is ejected from the laser engraver or otherwise ejected from the belt path. The cantilevered portion of the engraving target 102 may contain a transparent or semi-transparent area or window 120 to be engraved. A “safe zone” may be provided or created below the transparent window of the engraving target 102 (e.g., where the belt 104 “turns” around idle roller 110). Thus, when the transparent window is being engraved, the belt 104 is positioned, for example, down and away, so that any energy that penetrates the transparent window does not contact and / or damage the belt 104.

[0022] Using a Protection Member to Protect the Belt:

[0023] One potential disadvantage to cantilevering the engraving target over the edge of the belt path is that the location of the transparent window may be restricted to limited areas of the engraving target. For example, when the engraving target is a card, when cantilevering the card over the edge of the belt path, any target transparent window may be limited to a portion of the card that can be cantilevered over the edge of the belt path. Since a portion of the card must remain on the belt itself while the card is being engraved, any portion of the card having a target transparent window that remains over the belt can still create the risk of damage to the belt. The location of the transparent window on the engraving target may further be limited by the size of the engraving target and / or whether the laser source is fixed or movable. Moreover, the safe zone that the engraving target hangs over may be at or near an extreme edge of the laser’s usable range (where the beam of laser energy can be directed using one or more prisms or mirrors located between the laser source and the engraving target or by angling the card path). Positioning the engraving target at or near an extreme edge of the laser’s range (when the laser is fixed) may result in optical angle distortion (e.g., a keystone effect) that may result in a distorted engraved image or require compensation that may impact throughput due to the additional time required to calculate the compensation.

[0024] A way to reduce or eliminate the potential disadvantages discussed above is to create a safe zone directly beneath the laser using a protection member that diverts or protects the belt so that the belt is not in contact with the engraving target or substrate at a position directly beneath the laser source and is protected from being exposed to laser energy. Thus,the protection member may be located above the portion of the belt directly below or directly under the laser source. Stated differently, at least a portion of the protection member may be located between the laser source and the belt such that energy from the beam of laser energy generally does not reach and / or contact the belt.

[0025] In general, a protection member may include a series of rollers, one of which the belt can be diverted beneath, relative the laser source so that energy emitted by the laser may reach and / or contact the roller the belt is diverted beneath, but generally does not reach or contact the belt. In another example, the protection member may include rollers and a material plate (e.g., a metal plate) that can be located between the laser source and the belt so that when an engraving target with a transparent window is being engraved, laser energy generally does not contact the belt.

[0026] FIG. 2A and 2B illustrate an example of a cross section of a laser engraver transport mechanism 200 including a protection member. As illustrated in FIG. 2A, laser engraver transport mechanism 200 may include many of the same components as illustrated in FIG. 1. For example, the laser engraver transport mechanism 200 may include a transport mechanism including a belt 202, a drive roller 204, and multiple idle rollers 206, 210, 212, 214. The drive roller 204 and the multiple idle rollers 206, 210, 212, 214 may be configured to move the belt 202 to position the engraving target 222. Idle roller 214 can be added to the transport mechanism to provide extra drag on the belt 202, increase the wrap around the drive roller 204, and reduce slip of the belt 202 as it moves. A laser system 232 may be located above the laser engraver transport mechanism 200 and may contain a laser source and one or more mirrors (e.g., between the laser source and the engraving target) to direct a beam of laser energy toward the engraving target 222.

[0027] The laser engraver transport mechanism 200 may further include a protection member located substantially below the laser system 232. The protection member can include a first protection roller 216 and a second protection roller 224. The second protection roller 224 may be laterally spaced apart from the first protection roller 216. A third protection roller 226 may be located generally between the first protection roller 216 and the second protection roller 224 along a path of the belt 202. In an example, the third protection roller 226 may be provided in a same plane as the first and second protection rollers 216, 224. The third protection roller 226 may be located so that the belt 202 may be directed above or over the first protection roller 216, diverted beneath or below the third protection roller 226, and directed back above or over the second protection roller 216 (such as when the belt 202 is driven by the drive roller 204). Thus, as illustrated in FIG. 2A, a first portion of the belt 202may be located above (e.g., closer to, and able to support, the card, substrate, or other engraving target) the first protection roller 216, a second portion of the belt 202 may be located above (e.g., closer to, and able to support, the card, substrate, or other engraving target) the second protection roller 224, and a third portion of the belt 202 may be located below (e.g., away from the card, substrate, or other engraving target) the third protection roller 226. The third protection roller 226 may thus act or function as a buffer between the engraving target 222 and the belt 202. When the engraving target 222 includes a transparent window 208 to be engraved, laser energy that is transmitted through the transparent window 208 will contact the third protection roller 226 and not the belt 202. The third protection roller 226 may be formed from or made of a different material than the belt 202, so that the third protection roller 226 may not melt or otherwise be damaged by the laser energy and may not cause damage to the engraving target 222. For example, the third protection roller 226 may be formed from steel or stainless steel (e.g., an austenitic grade of stainless steel), which may be able to withstand repeated cycles of indirect laser energy (laser energy coming through the transparent window 208) with no or minimal damage. The protection rollers can be idle (non-driven) rollers such as the idle rollers 206, 210, 212, 214 of the transport mechanism.

[0028] As indicated previously, the laser engraver transport mechanism 200 may also include a fan duct 218 located below the protection rollers. The fan duct 218 may be sized and shaped so that a vacuum force may be directed around the protection member to hold or secure the engraving target 222 to the belt 202. For example, the fan duct 218 may include a lower portion, where the fan duct 218 interfaces with, for example, a fan or other vacuum source, that is substantially circular or other suitable shape and an upper portion that includes a concave portion below the first protection roller 216, the second protection roller 224, and the third protection roller 226 and redirects the vacuum force from the fan or other vacuum source around the protection member and to the belt. The upper portions of the fan duct 218 to the side of the first protection roller 216 and to the side of the second protection roller 224 may be substantially rectangular or other suitable shape. For example, the fan duct 218 may include an opening 236 that interfaces with the fan or other vacuum source, and an outer wall 238 that extends upward from the interface opening toward the belt path. The outer wall 238 may flare outward and may form a top surface that includes two engagement sides 234 such that the concave portion extends between the two engagement sides 234. In general, the shape of the fan duct may be varied or altered as desired to create the vacuum force around the protection member and directed to the belt based, for example, on factors such as the size,shape, and number of components of the protection member and / or the location of the protection member.

[0029] FIGS. 2B-2C illustrate an example of a view from above a portion of the laser engraver transport mechanism of FIG. 2A. Specifically, FIG. 2B shows the entire width of a belt 202 including a plurality of holes 220. As illustrated in FIG. 2B, the belt 202 may be inserted into the protection member (i.e., the protection rollers) so that the belt 202 threads or is weaved above the first protection roller 216, below the third protection roller 226, and above the second protection roller 224, as illustrated.

[0030] In FIG. 2C, the belt 202 has been made partially transparent to illustrate how particular holes in the plurality of holes 220 align with one or more securing members 228 in the top portion of the fan duct 218 as the belt 202 passes over the fan duct 218. The vacuum force may be communicated to a top side of the belt 202 through the securing members 228. The securing members 228 may align with one or more apertures or holes 220 in the belt 202 to secure an engraving target in place on the belt 202. In an example, the one or more securing members 228 may include one or more holes, slots, grooves, or another similar cut out, opening, negative space or void in the surface of the fan duct 218 to allow air flow through the surface of the fan duct 218.

[0031] In an example, when a fan or other vacuum source, connected with the fan duct 218 is operating or active, the one or more securing members 228 may allow for a vacuum force to be created between the plurality of holes 220 in the belt 202 and the one or more securing members 228. The created vacuum force can pinch or secure an engraving target (e.g., a card) to the belt 202 as the belt 202 moves, allowing for accurate placement of the engraving target relative to the laser source. Furthermore, the one or more securing members 228 may allow for an engraver that does not require using a traditional pinch roller to keep the engraving target in place. Pinch rollers may scratch or introduce other quality defects in the surface of a finished product, such as deformation or bending the finished engraving target or substrate. Thus, the vacuum force created by the one or more securing members 228 to keep the engraving target in place has the potential advantage of creating less waste as fewer finished engraving targets or substrates may be damaged and / or discarded. Additionally, using a belt instead of pinch rollers may allow the entire surface or substantially the entire surface of the engraving target to be engraved without having to reposition the engraving target as pinch rollers would cover a portion of the engraving target.

[0032] Thus, as shown in FIGS. 2B and 2C, the engagement sides 234 may include the one or more securing members 228 such that the one or more securing members 228 permit airflow through a top surface of the engagement sides 234. Furthermore, the concave portion of the fan duct 218 may extend or otherwise be located in such a manner to direct the vacuum flow around the protection member but the concave portion of the fan duct 218 may not include the securing members 228.

[0033] FIG. 2D illustrates an example of a view from above the laser engraver transport mechanism of FIG. 2A illustrating a material plate included with a protection member. As indicated above, additionally, or alternatively, the protection member may include a material plate 230. In an example, the material plate 230 may be used instead of, or in addition to, the third protection roller 226. The material plate may be formed from a metal such as aluminum, stainless steel (e.g., an austenitic grade of stainless steel), or steel. A surface of the material plate 230 such as a surface that may come into contact with the belt (e.g., an underside, a backside or the like) or the third protection roller 226, may include a material with a lower coefficient of friction than at least one of the material plate 230 or the belt 202 (e.g., Ultra High Molecular Weight Polyethylene (UMHWPE)) to prevent the belt 202 or the third protection roller 226 from slipping against the underside of the material plate 230. For example, the material plate 230 may be located above at least a portion of the third protection roller 226. In such an example, the third protection roller 226 may be located in a plane below the plane of the first protection roller 216 and the second protection roller 226.

[0034] In another example, the material plate 230 may be located between and in a same plane as the first protection roller 216 and the second protection roller 224. In another example, the material plate may be located in a plane below the plane of the first protection roller 216 and the second protection roller 224. More generally, the material plate 230 may be located or positioned in any suitable location that does not interfere with the engraving of the transparent window of an engraving target but blocks laser energy from passing through the window from reaching or contacting at least a portion of the belt 202.

[0035] In the example illustrated in FIG. 2D, a material plate 230, such as described above, may be located above the third protection roller 226. Use of the material plate 230 in addition to the third protection roller 226 may offer additional protection to the belt 202 from laser energy. As discussed above, in some examples the material plate 230 may be used in lieu of the third protection roller 226. Also, while FIG. 2D illustrates the third protection roller 226 in a same plane with the first protection roller 216 and the second protection roller 224, the third protection roller 226 may be in a lower plane than the first protection roller 216 and the second protection roller 224. In such an example, the material plate 230 may be locatedgenerally anywhere between the first protection roller 216 and the second protection roller 224.

[0036] In sum, the protection member may include rollers (e.g., the first and second roller) to, similar to the idle rollers of the transport mechanism, move the belt to aid in positioning the engraving target with respect to the laser source and / or the beam of laser energy. The protection member may also include a third roller and / or a material plate that can be positioned in a way that a portion of the belt may pass under the third roller and / or plate. Hence, the third roller and / or the plate may be located between the laser source and the belt so that radiation or energy from the laser source that may penetrate the transparent area of the engraving target cannot contact, and thus risk damaging, the belt.

[0037] Two-Belt Transport Mechanism

[0038] In another example embodiment, a laser engraver may utilize a two-belt transport mechanism in which the safe zone is created by a gap between the belts. Thus, any laser energy passing through the transparent window of the engraving target will generally not contact either of the two belts. Each transport mechanism may operate in substantially the same respect as discussed above for FIG. 1.

[0039] FIG. 3 illustrates an example side view of a two-belt transport mechanism 300 of a laser engraver. In an example, the two-belt transport mechanism 300 may include belts, such as first belt 302A and second belt 302B, that are each supported by rollers 306. One or more of the rollers 306 may be driven by motors 308 A and 308B. The belts 302 A and 302B may be coupled to a vacuum source 310, such as a regenerative vacuum blower or a fan. The vacuum source 310 may be shared by the belts 302A and 302B or each belt may be connected to its own vacuum source.

[0040] Fan ducts 316 may couple a negative pressure or vacuum force generated by the vacuum source 310 to exposed portions of the belts 302A and 302B. In some examples, the vacuum force may be communicated to a top side of the belts 302 A and 302B through a negative space, such as a hole or slot in the top of the fan ducts 316 that may align with one or more apertures or holes in the belts 302A and 302B to secure the engraving target 312 in place on the belts 302 A and 302B. Thus, when an engraving target 312 engages a top surface of one of the belts 302 A and 302B, the vacuum force adheres the engraving target 312 in place, and the adhered engraving target 312 can be driven along a processing axis when the belts 302 A and 302B are driven by the motors 308 A and 308B.

[0041] In an example, the engraving target 312 may be located such that a transparent portion of the engraving target 312 is located over a gap 318 between the belts 302A and302B. The gap 318 provides a safety zone or area in which laser energy from a laser system 314 may penetrate the transparent window of the engraving target 312 but will not damage either of the belts 302A and 302B, similar to the cantilevered example illustrated in FIG. 1. The laser system 314 may include a laser source and may also include one or more mirrors located between the laser source and the engraving target to direct the laser energy.

[0042] Thus, as illustrated in FIGS. 1-3, a laser engraver may utilize or include a single belt or multiple belts each operated by their own drive roller (or a roller driven by a motor). The protection members and fan duct described herein may be altered as desired or necessary to accommodate two belts and two drive rollers. The belts may be used to move the engraving target and position a transparent portion of the engraving target at a location where the belt or belts are diverted or otherwise protected (e.g., over a gap or a protection member such as a roller or material plate as discussed herein). It is also understood that the transport mechanism and / or the protection mechanism described herein may include additional components and may include any number of idle and / or drive rollers or any number of material plates as desired.

[0043] FIG. 4 illustrates an example of a method for protecting a transport mechanism of a laser engraver. The method 400 can include or comprise a number of Operations or Steps. The Steps described herein are examples only, and the method can omit one or more of the listed Steps, can repeat Steps, can include other Steps, or can execute the Steps concurrently, substantially simultaneously, or in another order, as appropriate or desired.

[0044] At Step 402 the method may include providing an engraving target on a transport mechanism of a laser engraver. The transport mechanism may include a belt to move the engraving target relative to a laser source. In an example, the engraving target may be a substrate, such as a card substrate. Examples of card substrates may include identification cards (e.g., government-issued licenses, or workplace identification cards), credit cards, bank cards, retailer reward cards, or the like. The engraving target may contain one or more transparent portions or transparent areas through which a portion of laser energy or radiation from the laser source can transmit through, penetrate, or the like.

[0045] Step 404 may include positioning the engraving target relative to the laser source. In an example, the laser source may be fixed in place, and the beam of radiation may be directed using one or more mirrors located between the laser source and the engraving target. In an example, at least a portion of the engraving target may be positioned below and substantially orthogonal to the laser source.

[0046] Step 406 may include locating a transparent window of the engraving target above at least a portion of a transport mechanism protection member or over a “safe zone,” as described previously. For example, the protection member may include one or more rollers, such as a first protection roller and a second protection roller spaced laterally apart from the first protection roller. A third protection roller may be located between the first protection roller and the second protection roller. The belt may be located on the transport mechanism such that a portion of the belt is directed above the first and second protection rollers and is diverted below the third protection roller. Stated differently, positioning the engraving target relative to the laser source in Step 404 may include locating the transparent area above a portion of the protection member where the belt is diverted or protected from the laser energy in Step 406. In another example, the third protection roller may be omitted and a material plate (e.g., a plate formed from a metal such as steel or stainless steel, such as an austenitic grade of stainless steel, may be located between the laser source and the belt and / or between the engraving target and the belt. Thus, similar to the example in which a third protection roller is used, the belt may be diverted under the material plate so that energy from the laser source that penetrates through the transparent area of the engraving target contacts the material plate and not the belt.

[0047] At Step 408, the method may include engraving at least a portion of the transparent area of the engraving target. Step 408 may include, for example, engraving an image or other logo on a portion of the transparent window over the protection member while the belt is protected by third protection roller and / or the material plate. Additionally, or alternatively, one or more of the transparent areas or windows may be positioned so as to be cantilevered over an edge of the transport mechanism (as illustrated and discussed above for FIG. 1) and the laser energy directed to the portion of the target that is cantilevered over the edge using the one or more mirrors. In another example, the laser engraver may utilize a two-belt system such as that shown and described in FIG. 3, and the “safe zone” may be located in a gap between the belts over which the transparent area may be located during engraving.

[0048] Example l is a laser engraving system, comprising: a transport mechanism to position an engraving target relative to a laser source, the transport mechanism comprising: a belt to move the engraving target; and a drive roller to drive the belt; and a safe zone configured to protect at least a portion of the belt from a beam of laser energy.

[0049] In Example 2, the subject matter of Example 1 optionally includes the laser source, wherein the laser source is configured to emit a beam of laser radiation toward the engraving target.

[0050] In Example 3, the subject matter of any one or more of Examples 1-2 optionally include wherein the transport mechanism further comprises a plurality of idle rollers to increase wrap of the belt around the drive roller.

[0051] In Example 4, the subject matter of any one or more of Examples 1-3 optionally include wherein the safe zone includes a protection member configured to be positioned below the laser source, such that at least a portion of the protection member is located between the laser source and the belt such that energy from the beam of laser energy is at least partially blocked by at least a portion of the protection member from making contact with the belt.

[0052] In Example 5, the subject matter of Example 4 optionally includes wherein the protection member includes: a first protection roller; and a second protection roller spaced apart from the first protection roller.

[0053] In Example 6, the subject matter of Example 5 optionally includes wherein the protection member further includes: a third protection roller located between the first protection roller and the second protection roller.

[0054] In Example 7, the subject matter of Example 6 optionally includes wherein a first portion of the belt is directed above a top surface of the first protection roller, a second portion of the belt is directed above a top surface of the second protection roller, and a third portion of the belt is diverted below a bottom surface of the third protection roller.

[0055] In Example 8, the subject matter of any one or more of Examples 6-7 optionally include wherein the protection member further includes: a material plate located at least one of above at least a portion of the third protection roller or located between the first protection roller and the second protection roller.

[0056] In Example 9, the subject matter of Example 8 optionally includes wherein, a first portion of the belt is directed above a top surface of the first protection roller, a second portion of the belt is directed above a top surface of the second protection roller, and a third portion of the belt is diverted below a bottom surface of the material plate.

[0057] In Example 10, the subject matter of Example 9 optionally includes a material on the bottom surface of the material plate with a lower coefficient of friction than at least one of the material plate or the belt.

[0058] In Example 11, the subject matter of any one or more of Examples 6-10 optionally include wherein the third protection roller is located below a plane including the first protection roller and the second protection roller.

[0059] In Example 12, the subject matter of any one or more of Examples 5-11 optionally include a fan duct; and a vacuum source.

[0060] In Example 13, the subject matter of Example 12 optionally includes wherein a surface of the fan duct includes a securing member to align with a hole in the belt.

[0061] In Example 14, the subject matter of Example 13 optionally includes wherein the fan duct is shaped such that when the vacuum source is in operation, the securing member communicates a vacuum force through the hole in the belt to maintain a positive engagement between the engraving target and at least one of the protection member or the belt during engraving.

[0062] In Example 15, the subject matter of Example 14 optionally includes wherein a first part of a top portion of the fan duct is concave below the protection member.

[0063] In Example 16, the subject matter of Example 15 optionally includes wherein a second part of the top portion at least one of to an outside of the first protection roller or to an outside of the second protection roller is substantially rectangular.

[0064] Example 17 is a method for protecting a transport mechanism of a laser engraver, the method comprising: providing an engraving target on a transport mechanism of a laser engraver, the transport mechanism including a belt to move the engraving target; positioning the engraving target relative to a fixed laser source of the laser engraver using the transport mechanism, wherein positioning the engraving target includes locating a transparent area of the engraving target above a portion of the transport mechanism where the belt is protected from laser energy; and engraving at least a portion of the transparent area of the engraving target using the fixed laser source.

[0065] In Example 18, the subject matter of Example 17 optionally includes wherein positioning the engraving target relative to the fixed laser source includes locating the transparent area above at least a portion of a transport mechanism protection member, the transport mechanism protection member including: a first protection roller; a second protection roller spaced apart from the first protection roller; and at least one of: a third protection roller located between the first protection roller and the second protection roller, or a material plate located between the first protection roller and the second protection roller.

[0066] In Example 19, the subject matter of Example 18 optionally includes wherein when the transport mechanism protection member includes the third protection roller, wherein a first portion of the belt is directed above a top surface of the first protection roller, a second portion of the belt is directed above a top surface of the second protection roller, and a third portion of the belt is diverted below a bottom surface of the third protection roller.

[0067] In Example 20, the subject matter of any one or more of Examples 18-19 optionally include wherein when the transport mechanism protection member includes the material plate, a first portion of the belt is directed above the first protection roller, a second portion of the belt is directed above the second protection roller, and a third portion of the belt is diverted below the material plate.

[0068] In Example 21, the subject matter of any one or more of Examples 18-20 optionally include wherein when the transport mechanism protection member includes the material plate and the third protection roller, the third protection roller is located in a plane located below the first protection roller and the second protection roller.

[0069] In Example 22, the subject matter of any one or more of Examples 17-21 optionally include wherein positioning the engraving target includes locating a transparent area of the engraving target above a portion of the transport mechanism where the belt is protected from the laser energy includes cantilevering a portion of the engraving target over an edge of the transport mechanism, and wherein engraving at least a portion of the transparent area of the engraving target includes directing a beam of laser energy from the fixed laser source to the portion of the engraving target over the edge of the transport mechanism.

[0070] As used herein, the terms “substantially” or “generally” refer to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. For example, an object that is “substantially” or “generally” enclosed would mean that the object is either completely enclosed or nearly completely enclosed. The exact allowable degree of deviation from absolute completeness may in some cases depend on the specific context. However, generally speaking, the nearness of completion will be so as to have generally the same overall result as if absolute and total completion were obtained. The use of “substantially” or “generally” is equally applicable when used in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result. For example, an element, combination, embodiment, or composition that is “substantially free of’ or “generally free of’ an element may still actually contain such element as long as there is generally no significant effect thereof.

[0071] The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments may be used, such as by one of ordinary skill in the art upon reviewing the above description. The Abstract is to allow the reader to quickly ascertain the nature of the technical disclosure and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above DetailedDescription, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment. The scope of the embodiments should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

Claims

CLAIMSWHAT IS CLAIMED IS:

1. A laser engraving system, comprising: a transport mechanism to position an engraving target relative to a laser source, the transport mechanism comprising: a belt to move the engraving target; and a drive roller to drive the belt; and a safe zone configured to protect at least a portion of the belt from a beam of laser energy.

2. The laser engraving system of claim 1, further comprising: the laser source, wherein the laser source is configured to emit a beam of laser radiation toward the engraving target.

3. The laser engraving system of any of claims 1-2, wherein the transport mechanism further comprises a plurality of idle rollers to increase wrap of the belt around the drive roller.

4. The laser engraving system of any of claims 1-3, wherein the safe zone includes a protection member configured to be positioned below the laser source, such that at least a portion of the protection member is located between the laser source and the belt such that energy from the beam of laser energy is at least partially blocked by at least a portion of the protection member from making contact with the belt.

5. The laser engraving system of claim 4, wherein the protection member includes: a first protection roller; and a second protection roller spaced apart from the first protection roller.

6. The laser engraving system of claim 5, wherein the protection member further includes: a third protection roller located between the first protection roller and the second protection roller.

7. The laser engraving system of claim 6, wherein a first portion of the belt is directed above a top surface of the first protection roller, a second portion of the belt is directed above a top surface of the second protection roller, and a third portion of the belt is diverted below a bottom surface of the third protection roller.

8. The laser engraving system of any of claims 6-7, wherein the protection member further includes: a material plate located at least one of above at least a portion of the third protection roller or located between the first protection roller and the second protection roller.

9. The laser engraving system of claim 8, wherein, a first portion of the belt is directed above a top surface of the first protection roller, a second portion of the belt is directed above a top surface of the second protection roller, and a third portion of the belt is diverted below a bottom surface of the material plate.

10. The laser engraving system of claim 9, further comprising: a material on the bottom surface of the material plate with a lower coefficient of friction than at least one of the material plate or the belt.

11. The laser engraving system of any of claims 6-10, wherein the third protection roller is located below a plane including the first protection roller and the second protection roller.

12. The laser engraving system of any of claims 5-11, further comprising: a fan duct; and a vacuum source.

13. The laser engraving system of claim 12, wherein a surface of the fan duct includes a securing member to align with a hole in the belt.

14. The laser engraving system of claim 13, wherein the fan duct is shaped such that when the vacuum source is in operation, the securing member communicates a vacuum force through the hole in the belt to maintain a positive engagement between the engraving target and at least one of the protection member or the belt during engraving.

15. The laser engraving system of claim 14, wherein a first part of a top portion of the fan duct is concave below the protection member.

16. The laser engraving system of claim 15, wherein a second part of the top portion at least one of to an outside of the first protection roller or to an outside of the second protection roller is substantially rectangular.

17. A method for protecting a transport mechanism of a laser engraver, the method comprising: providing an engraving target on a transport mechanism of a laser engraver, the transport mechanism including a belt to move the engraving target; positioning the engraving target relative to a fixed laser source of the laser engraver using the transport mechanism, wherein positioning the engraving target includes locating a transparent area of the engraving target above a portion of the transport mechanism where the belt is protected from laser energy; and engraving at least a portion of the transparent area of the engraving target using the fixed laser source.

18. The method of claim 17, wherein positioning the engraving target relative to the fixed laser source includes locating the transparent area above at least a portion of a transport mechanism protection member, the transport mechanism protection member including: a first protection roller; a second protection roller spaced apart from the first protection roller; and at least one of: a third protection roller located between the first protection roller and the second protection roller, or a material plate located between the first protection roller and the second protection roller.

19. The method of claim 18, wherein when the transport mechanism protection member includes the third protection roller, wherein a first portion of the belt is directed above a top surface of the first protection roller, a second portion of the belt is directed above a top surface of the second protection roller, and a third portion of the belt is diverted below a bottom surface of the third protection roller.

20. The method of any of claimsl8-19, wherein when the transport mechanism protection member includes the material plate, a first portion of the belt is directed above the first protection roller, a second portion of the belt is directed above the second protection roller, and a third portion of the belt is diverted below the material plate.

21. The method of any of claims 18-20, wherein when the transport mechanism protection member includes the material plate and the third protection roller, the third protection roller is located in a plane located below the first protection roller and the second protection roller.

22. The method of any of claims 17-21, wherein positioning the engraving target includes locating a transparent area of the engraving target above a portion of the transport mechanism where the belt is protected from the laser energy includes cantilevering a portion of the engraving target over an edge of the transport mechanism, and wherein engraving at least a portion of the transparent area of the engraving target includes directing a beam of laser energy from the fixed laser source to the portion of the engraving target over the edge of the transport mechanism.

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