Laser method and system of scribing graphics

• US 5,990,444 A
• Filed: 10/11/1996
• Issued: 11/23/1999
• Est. Priority Date: 10/30/1995
• Status: Expired due to Term

• Current Assignee: RevoLaze LLC (Lear Corporation)
• Original Assignee: Darryl Costin
• Inventors: Costin, Darryl J.
• Primary Examiner(s): Evans, Geoffrey S.
• Application Number:
  US08/729,493
• Time in Patent Office: 1,138 Days
• Field of Search: 219/121.72, 219/121.68, 219/121.69, 219/121.67, 219/121.78, 219/121.8, 219/121.65, 219/121.66, 219/121.6, 219/121.61, 8/444, 347/253, 430/20
• US Class Current: 219/121.69
• CPC Class Codes: B23K 26/03 Observing, e.g. monitoring, the workpiece
• CPC Class Codes: B23K 26/0344 Observing the speed of the workpiece
• CPC Class Codes: B23K 26/0648 comprising lenses
• CPC Class Codes: B23K 26/0665 by beam condensation on the workpiece, e.g. for focusing
• CPC Class Codes: B23K 26/082 Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
• CPC Class Codes: B41M 5/24 Ablative recording, e.g. by burning marks; Spark recording marking by high energetic means, e.g. by laser otherwise than burning or ablative removal B41M5/26; materials or methods for recording or reproduction by optical means G11B7/00
• CPC Class Codes: D06B 11/0096 to get a faded look
• CPC Class Codes: D06C 23/02 by singeing, teasing, shearing, etching or brushing
• CPC Class Codes: D06M 10/005 Laser beam treatment
• CPC Class Codes: D06P 5/001 Special chemical aspects of printing textile materials
• CPC Class Codes: D06P 5/15 Locally discharging the dyes
• CPC Class Codes: D06P 5/2005 Treatments with alpha, beta, gamma or other rays, e.g. stimulated rays
• CPC Class Codes: G06K 1/126 by photographic or thermographic registration recording apparatus for measuring instruments G01D15/00

Abstract

A laser method scribes graphics on materials. The method relates to the identification and understanding of a new energy measurement called energy density per unit time, and the identification and simultaneous control of the laser operating parameters which influence this energy measurement. Once a range of energy density per unit time is determined for scribing a desired graphic on a given material, the energy density per unit time can be controlled to stay within that range to achieve desired results in a repeatable fashion. In a preferred embodiment, the material is one of a group of fabric, leather and vinyl materials. In this embodiment, the energy density per unit time can be controlled to substantially avoid complete carbonization, melting and/or burnthrough of the material.

Claims

1. A laser method of forming a graphic on a material comprising:

scribing the material with a laser beam and controlling an energy density per unit time during the scribing, where the energy density per unit time is defined as;

##EQU3## where continuous power is a continuous power output of the laser during the scribing, area of spot is an area of a spot formed by the laser beam on the material when the laser beam is stationary relative to the material, and speed is a speed of the laser beam relative to the material during the scribing, wherein the material is one of a fabric material, a leather material, or a vinyl material, and wherein said energy density per unit time is controlled in a way to prevent undesired carbonization, melting or burn-through.

2. The laser method defined in claim 1 wherein a range of energy density per unit time is determined for scribing a desired graphic on a given material, and the energy density per unit time is controlled to stay within the range.

3. The laser method defined in claim 2 wherein the material is selected from the group consisting of fabrics, leathers and vinyls.

4. The laser method defined in claim 3 wherein the energy density per unit time is controlled to substantially avoid complete carbonization, melting and burnthrough of the material while forming a visible graphic.

5. The laser method defined in claim 4 wherein the energy density per unit time is controlled to stay within a range of from about 0.04 watts-sec/mm³ to about 15.81 watts-sec/mm³.

6. The laser method defined in claim 4 wherein the energy density per unit time is controlled to stay within a range of from about 0.11 watts-sec/mm³ to about 6.52 watts-sec/mm³.

7. The laser method defined in claim 3 wherein a graphic image is formed on denim by scribing at an energy density per unit time within a range of from about 0.03 watts-sec/mm³ to about 9.37 watts-sec/mm³.

8. The laser method defined in claim 3 wherein a sandblasted look is formed on a material selected from the group consisting of denim and khaki, by scribing at an energy density per unit time within a range of from about 0.09 watts-sec/mm³ to about 8.07 watts-sec/mm³.

9. The laser method defined in claim 3 wherein a graphic selected from the group consisting of logos and identification is formed on denim by scribing at an energy density per unit time within a range of from about 0.03 watts-sec/mm³ to about 9.37 watts-sec/mm³.

10. The laser method defined in claim 3 wherein a graphic selected from the group consisting of logos and identification is formed on a material selected from the group consisting of leathers and vinyls, by scribing at an energy density per unit time within a range of from about 0.21 watts-sec/mm³ to about 9.38 watts-sec/mm³.

11. The laser method defined in claim 3 wherein the material is a fabric selected from the group consisting of denim, cotton sheet, polyester, lycra, corduroy, velour, organza, rayon, nylon, acetate, wool, natural and artificial silk, acetate, flax, polyamide, lavsan, half wool, raincoat fabric, elastomer treated nonwoven polyester, woven and nonwoven canvas, and blends thereof.

12. The laser method defined in claim 11 wherein the fabric is denim.

13. The laser method defined in claim 1 wherein a mirror controls movement of the laser beam during the scribing.

14. The laser method defined in claim 1 wherein the graphic is formed with a greyscale by scribing different portions of the graphic at different levels of energy density per unit time to form different shades without completely penetrating the material.

15. The laser method defined in claim 1 wherein the graphic is formed in a unit application on a portion of an article.

16. A method as in claim 1, further comprising selecting an energy density per unit time that is optimized for the material being processed.

17. A laser method of forming a graphic on a material comprising :

scribing the material with a laser beam and controlling an energy density per unit time during the scribing, where the energy density per unit time is defined as;

##EQU4## where continuous power is a continuous power output of the laser during the scribing, area of spot is an area of a spot formed by the laser beam on the material when the laser beam is stationary relative to the material, and speed is a speed of the laser beam relative to the material during the scribing, wherein the energy density per unit time is continuously changed during the scribing.

18. The method defined in claim 17 wherein a sandblasted look is formed on the material by continuously changing the energy density per unit time during the scribing.

19. A laser method of forming a graphic on a material comprising:

scribing the material with a laser beam and controlling an energy density per unit time during the scribing, where the energy density per unit time is defined as;

##EQU5## where continuous power is a continuous power output of the laser during the scribing, area of spot is an area of a spot formed by the laser beam on the material when the laser beam is stationary relative to the material, and speed is a speed of the laser beam relative to the material during the scribing, wherein the graphic is formed with a greyscale by;

entering the graphic into a computer,

converting the graphic to a black and white image by a process which is one of error diffusion, halftone, pattern dither, threshold, and diffusion dither,

converting the graphic to a numerical control program language, and

scribing the graphic on a material under control of the computer.

20. A laser method of forming a graphic on a material comprising:

scribing the material with a laser beam and controlling an energy density per unit time during the scribing, where the energy density per unit time is defined as;

##EQU6## where continuous power is a continuous power output of the laser during the scribing, area of spot is an area of a spot formed by the laser beam on the material when the laser beam is stationary relative to the material, and speed is a speed of the laser beam relative to the material during the scribing, wherein the graphic is formed with a greyscale by repeating the scribing on portions of the graphic, with different portions of the graphic scribed a different number of times to form different shades.

21. A laser method of forming a graphic on a material comprising:

scribing the material, which is one of a fabric material, a leather material, or a vinyl material, with a laser beam and controlling an energy density per unit time during the scribing by controlling all of continuous power output of the laser during the scribing, area of a spot formed by the laser beam on the material when the laser beam is stationary relative to the material, and speed of the laser beam relative to the material during the scribing in a way that prevents undesired carbonization, melting or burn through of the material.

22. The laser method defined in claim 21 wherein a range of energy density per unit time is determined for scribing a desired graphic on a given material, and the energy density per unit time is controlled to stay within the range.

23. The laser method defined in claim 22 wherein the energy density per unit time is controlled to substantially avoid complete carbonization, melting and burnthrough of the material while forming a visible graphic.

24. The laser method defined in claim 22 wherein the material is a fabric selected from the group consisting of denim, cotton sheet, polyester, lycra, corduroy, velour, organza, rayon, nylon, acetate, wool, natural and artificial silk, acetate, flax, polyamide, lavsan, half wool, raincoat fabric, elastomer treated nonwoven polyester, woven and nonwoven canvas, and blends thereof.

25. The laser method defined in claim 24 wherein the fabric is denim.

26. A system which operates to form a desired pattern on a material, comprising:

a controllable laser, having command elements which command movement of an output of said laser to different locations;

a controller, operating to produce outputs indicative of the desired pattern to be formed, said outputs controlling said controllable laser to control a position of marking thereof, wherein said material is one of a fabric, a leather or a vinyl, and said controller controlling an energy density per unit time that is output from said laser and which depends on all of the laser power, laser speed and laser spot size to stay within a desired range for said material, and wherein said energy density per unit time is set to a range which forms a perceivable graphic on said material without causing said undesired carbonization, melting or burn through of the material.

27. A system as in claim 26, wherein said energy density per unit time is proportional to power of the laser divided by spot area and speed of movement of the laser beam.

28. A system as in claim 26, wherein said laser is a CO₂ laser.

29. A system as in claim 26, wherein said energy density per unit time and per unit area is between 0.11 and 6.52 watts-sec/mm³.

30. A system as in claim 26, wherein said material is denim, said energy density per unit time is selected such that a conventional denim color is faded by application of said laser.

31. A system as in claim 26, wherein said energy density per unit time and per unit area is variable.

32. A system which operates to form a desired pattern on a denim material, comprising:

a controllable laser, having command elements which command movement of an output of said laser to different locations;

a controller, operating to produce outputs indicative of the desired pattern to be formed, said outputs controlling said controllable laser to control a position of marking thereof, said controller controlling an energy density per unit time that is output from said laser to stay within a desired range for said material, wherein said energy density per unit time is selected such that a conventional denim indigo color is faded to an lightened indigo color.

33. A method of marking material using a laser, comprising:

identifying a material which is to be marked, which is one of a fabric, a leather or a vinyl material;

applying a laser at a specified amount of energy density per unit time and per unit area which avoids undesired carbonization, melting or burn-through, to an area of said material to change some perceivable characteristic of said area of said material.

34. A method as in claim 33, wherein said energy density per unit time depends on power.

35. A system as in claim 33, wherein said energy density per unit time depends on spot area.

36. A system as in claim 33, wherein said energy density per unit time depends on speed.

37. A system as in claim 33, wherein said energy density per unit time depends on all of power, spot area and speed.

38. A system as in claim 33, wherein said energy density per unit time and per unit area is between 0.11 and 6.52 watts-sec/mm³.

39. A method as in claim 33 further comprising selecting an energy density per unit time that is optimized for the material being processed.

40. A system which operates to form a simulated sandblast pattern on a material, comprising:

a working surface, having an area for holding the material on which the simulated sandblast pattern is to be formed;

a controllable laser, having command elements which command movement of an output of said laser to different locations on said working surface;

a controller, storing a pattern which when output on said material will cause the simulated sandblast pattern, said controller operating to produce outputs indicative of the pattern, said outputs controlling said controllable laser to control a position of marking thereof.

41. A system as in claim 40, said controller controlling energy density per unit time that is output from said laser to stay within a desired range for said material and to change at different times during a scribing operation.

42. A system as in claim 41, said controller controlling said energy density per unit time and per unit area to selectively fade a color of said material.

43. A system as in claim 42, wherein said material is denim, and a portion of said color is faded to between completely faded and 30% of its original color.

44. A system as in claim 42, wherein said output is controlled according to a graphic image.

45. A system as in claim 44, wherein said graphic image is a black and white image indicating a greyscale image.

46. A method of scribing a desired pattern on a material, comprising:

obtaining an indication of the desired pattern;

using a controllable movable laser, having command elements which command movement of an output of said laser to different locations on said working surface;

controlling said laser to produce outputs indicative of the desired pattern to be formed based on said indication, said outputs controlling said controllable laser to control a position of marking thereof, said controller controlling an energy density per unit time that is output from said laser to stay within a controlled range of energy per unit time and per unit area for said material, which does not cause undesired carbonization, melting or vaporization for said material, and said material is one of a fabric material, a leather material or a vinyl material, and wherein said energy density per unit time can be different for different materials.

47. A method as in claim 46, wherein said controllable range of energy is proportional to power of the laser divided by spot area and speed of movement of the laser beam.

48. A method as in claim 47, wherein said material is denim, and said controllable range of energy density per unit time and per unit area is selected such that a conventional denim color is faded by application of said laser.

49. A method of scribing a desired pattern on a material, comprising:

obtaining information indicative of the desired pattern to be formed;

determining first portions of said pattern which are to be formed to have different characteristics than second portions of said pattern;

controlling a controllable, movable laser to produce an output based on laser beam outputs indicative of the desired pattern to be formed based on said information, and said determination of said first portions and second portions, to form said information of said first portion on said material in a first pass, and to form said information of said second portion on said material during a second pass, both said first and second passes of scribing being controlled to stay within a controlled range of energy per unit time and per unit area.

50. A method as in claim 49, wherein said range of energy is selected based on a property of said material.

51. A method as in claim 49, wherein said first pass of scribing uses a different range of energy than said second pass.

52. A method as in claim 51, wherein part of said first pass overlaps part of said second pass.

53. A method as in claim 51, wherein an entirety of said first pass overlaps said second pass.

54. A method as in claim 49, wherein said range of energy is proportional to power of the laser divided by spot area and divided by speed of movement of the laser beam.

55. A method of scribing a pattern on a material based on an input image, comprising:

obtaining a computer readable file indicating said input image;

converting the computer readable file to a two-colored image of a type that includes greyscale information about the image and which simulates the greyscale information using said two-colored image;

controlling a controllable laser to produce an output laser beam based on said two colored image, to form on the material based on said two colored image.

56. A method as in claim 55, wherein said laser is controlled to deliver a specified energy density to each area on the material.

57. A method as in claim 56, wherein said specified energy density is an energy density per unit time which is proportional to power of the laser divided by spot area and speed of movement of the laser beam.

58. A method as in claim 56, wherein said converting comprises one of error diffusion, halftone, pattern dither, threshold or diffusion dither.

59. A method as in claim 55, wherein said converting comprises one of error diffusion, halftone, pattern dither, threshold or diffusion dither.

60. A system which operates to form a desired pattern on a material, comprising:

a controllable laser, having an output which is controllable to control an amount of energy produced and to control a position of application of said energy; and

a controller, operating to produce outputs indicative of the desired pattern to be formed, said outputs controlling said controllable laser to control positions of said laser according to information indicating said pattern, and to control an amount of output of said laser, said controller controlling an amount of energy which will be delivered to any area of said material to stay within a desired range of amount of energy for said material, said desired range of energy being a range that will prevent undesired burning, carbonization or burn through on a desired material which is one of a fabric material, a leather material or a vinyl material.

61. A method of scribing a simulated stitched pattern on a material, comprising:

obtaining information which is indicative of a stitched pattern;

using a controllable movable laser, having command elements which command movement of an output of said laser to different locations on said working surface;

controlling said laser to produce outputs indicative of the information indicative of the stitched pattern, which turns said laser on and off to simulate said stitched pattern based on said information.

62. A method as in claim 61, wherein said outputs control said controllable laser to control a position of marking thereof, said controller controlling an energy density per unit time that is output from said laser to stay within a controlled range of energy density per unit time for said material.

63. A method of marking a material using a laser, comprising:

determining a greyscale graphic image indicating a desired pattern to be formed;

processing said graphic image to change the greyscale graphic image into a black and white image which simulates the greyscale image;

applying said black and white image to a controllable marking device of a type that cannot accept directly information in the form of said greyscale image, to thereby control said controllable marking device according to information contained in said black and white image using said marking device to mark a material in a way that does not undesirably carbonize, melt or perforate the material.

64. A method as in claim 63, further comprising using said marking device to mark a material.

65. A method as in claim 64, further comprising maintaining said marking device to output a specified amount of energy per unit time and per unit area based on said material to avoid perforating the material.

66. A method as in claim 63, wherein said processing produces a dithered image.

67. A method of marking a material using a laser, comprising:

determining a greyscale graphic image indicating a desired pattern to be formed;

processing said graphic image to change the greyscale graphic image into a black and white image which simulates the greyscale image;

applying said black and white image to a controllable laser of a type that cannot accept directly information in the form of said greyscale image, to thereby control said controllable laser according to information contained in said black and white image; and

applying an output of said controllable laser to a material to be processed;

wherein said applying comprises maintaining an output energy per unit time and per unit area within a specified range which avoids undesired carbonization, melting or burn-through.

68. A system which operates to change a color of a portion of a material, comprising:

a controllable laser, having command elements which command movement of an output of said laser to different locations, said controllable laser including a controller, operating to produce outputs which control the output of the laser to control a position of marking thereof, said controller controlling an energy density per unit time that is output from said laser within a specified range to change the color of the material without completely carbonizing, melting or perforating the material, where the material is one of fabric, vinyl or leather.

69. A method of marking a material, comprising:

identifying a material to be processed which is one of a fabric material, a vinyl material or a leather material;

determining an amount of energy per unit time and per unit area which, when output from a laser on to said material to be processed, will produce a specified effect on said material without undesirable burning, melting-through or carbonizing the material; and

operating the laser with said specific material at said specific amount of energy per unit time and per unit area.

70. A method as in claim 69, where said specified effect is a change of color of said material.

71. A method as in claim 70, where said specified effect is a change of color of said material.

72. A method of marking a material, comprising:

determining an amount of energy per unit time and per unit area which, when output from a laser on to said material to be processed, which is one of a fabric type material, a vinyl type material or a leather type material, will produce a specified effect on said material without undesirable burning, melting-through or carbonizing the material; and

operating a controllable laser with said specific material at said specific amount of energy per unit time and per unit area.