Automated Door Manufacturing with Wood Grain Replication
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Solution Overview
Problem
There is a need for an automated system that can produce synthetic components with a wood-like appearance, addressing the destruction of old growth forests, improving insulation, reducing carbon footprint, and providing secure and hurricane-resistant doors without the use of real wood.
Innovation Solution
A computer-controlled automated system that uses sensors to read tray identifiers, connecting with a production client device to match work orders for faster processing, applying base coats, glazes, and top coats with precise temperature control, enabling the production of doors with a wood-like appearance using polymer and fiberglass materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If real wood is used to manufacture doors, then the aesthetic appeal and natural appearance are improved, but the destruction of old growth forests and environmental harm worsen
Solution Approach 1:
The patent applies the copying principle by creating synthetic doors that replicate the visual appearance of real wood through detailed imaging technology. The system captures high-resolution images of actual wood grain patterns and reproduces them on synthetic door surfaces, achieving a convincing wood-like aesthetic without using real wood materials, thereby eliminating forest destruction while maintaining visual appeal
Solution Approach 2:
The patent employs composite materials by combining synthetic substances (such as fiberglass or polymer resins) with embedded imaging layers to create doors that mimic wood appearance. This composite structure allows the door to have the desired aesthetic qualities of real wood while being composed entirely of sustainable, non-wood materials
2Adaptability or versatility
If manual or semi-automated techniques are used for door manufacturing, then flexibility and customization are improved, but labor requirements and production time worsen
Solution Approach 1:
The patent applies preliminary action by pre-capturing and storing high-resolution images of various wood grain patterns and door designs in a database before the actual manufacturing process. This allows the automated system to quickly retrieve and apply different designs during production, enabling rapid customization without manual intervention for each design selection, thus maintaining versatility while significantly reducing production time
Solution Approach 2:
The patent implements dynamics by creating an automated manufacturing system that can dynamically switch between different door designs and configurations based on digital inputs. The system can adapt to various customization requirements by programmatically adjusting manufacturing parameters, allowing flexible production of different door styles, sizes, and patterns without the slow reconfiguration required in manual processes
3Device complexity
If traditional manufacturing processes are used, then simplicity of process is improved, but energy consumption and volatile organic fumes worsen
Solution Approach 1:
The patent applies mechanics substitution by replacing traditional mechanical spraying and finishing processes with a digital imaging and deposition system. Instead of using complex multi-step painting and staining processes that consume energy and emit volatile organic compounds, the system uses digital image transfer and controlled material deposition to achieve the wood-like appearance, simplifying the process while reducing energy consumption and harmful emissions
Data Source
AI summary
A system for creating a wood like appearance on a synthetic component including a sales client device, a network, computer instructions for creating a work order, a tray with scannable tray identifier to hold a synthetic component, a production client device connected to the network with computer instructions for applying a base coat, a glaze, and a top coat to the synthetic component as it automatically moves on a conveyer system a portion of which is connected to the production client device. A scannable tray identifier with a plurality of sensors link the tray identifier to the work order for authenticating and validating the location of the tray on the conveyor system, or initiating an alerting device. The system has a plurality of temperature control environments to simultaneously control heating of the synthetic component while spraying, drying and UV curing with spray treatment device.