Method for manufacturing a cuttable cladding panel with a matching pattern
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Solution Overview
Problem
Existing cladding panels with irregular patterns of lines, veins, and strips cannot be cut to different sizes while maintaining pattern continuity, limiting their adaptability to various substrates and sizes.
Innovation Solution
A manufacturing method for cuttable cladding panels with an irregular pattern, involving design and manufacturing phases where transverse and longitudinal cutting lines are defined to intersect with the pattern elements, allowing the panels to be cut into different lengths and widths while maintaining pattern continuity by ensuring intersecting points align and coincide when panels are joined.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cladding panels with irregular patterns are manufactured with continuous pattern design, then pattern continuity between adjacent panels is achieved, but the panels cannot be cut to different sizes without losing pattern continuity
Solution Approach 1:
The irregular pattern is segmented at predefined cutting lines, creating matching pattern segments that can be separated and reassembled. The pattern is divided into multiple sections with corresponding segments on adjacent panels that can be matched after cutting, allowing both pattern continuity and size adaptability.
Solution Approach 2:
The pattern design preliminarily incorporates cutting lines and matching segments before the actual cutting process. By pre-defining where cuts will occur and ensuring pattern segments align at these predetermined locations, the system enables subsequent cutting operations while maintaining pattern continuity.
2Manufacturing precision
If cladding panels are designed with regular geometric patterns, then manufacturing precision is easier to achieve, but the panels lack the natural stone appearance and irregular pattern characteristics
Solution Approach 1:
The pattern exhibits local irregularity within defined segments while maintaining overall structural regularity. Each local section contains unique irregular vein patterns that simulate natural stone, while the global structure follows a systematic grid of cutting lines and matching segments that ensures manufacturability and assembly precision.
3Adaptability or versatility
If cladding panels are cut to adapt to different substrate sizes, then adaptability to various applications is improved, but pattern continuity between adjacent panels is lost
Solution Approach 1:
Matching pattern segments are created as corresponding copies on adjacent panels. Each panel contains replicated pattern elements at predetermined locations that serve as templates for matching adjacent panels, enabling the reconstruction of continuous patterns after cutting and reassembly.
4Ease of manufacture
If existing cladding panels are manufactured without predefined cutting lines, then manufacturing process is simpler, but cutting the panels destroys the pattern continuity
Solution Approach 1:
The manufacturing process preliminarily incorporates cutting line definitions and pattern segmentation before the cutting operation. By pre-marking and pre-positioning pattern segments relative to cutting lines during manufacturing, the subsequent cutting process becomes a precise separation operation rather than a exploratory cut, ensuring pattern continuity is maintained.
Data Source
AI summary
The present invention relates to a cuttable cladding panel with a matching pattern, the use, and the design method thereof. The cladding panel comprises an irregular pattern (10) of elongated lines, veins, and/or strips; transverse cutting lines (20) all of them cutting through the pattern at identical transverse intersecting points symmetrical with respect to a longitudinal axis of symmetry (SL); pairs of longitudinal cutting lines (30) symmetrical with respect to the longitudinal axis of symmetry (SL), each pair of longitudinal cutting lines cutting through the pattern at identical longitudinal intersecting points; with said cutting lines crossing one another at corner points (P); wherein each transverse intersecting point (21) is at the same distance from a corner point (P) as a corresponding longitudinal intersecting point (31); with two parts obtained by cutting the cladding panel (1) along any cutting line having a matching and continuous irregular pattern (10).