Engineered Stone Slab Veining via Masking Image Alignment
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Solution Overview
Problem
Existing methods for manufacturing engineered stone slabs struggle to replicate the natural, random veining and color patterns of natural stones due to limitations in manufacturing processes, resulting in slabs with unnatural, surface-only printed designs that lack cohesion and uniformity.
Innovation Solution
The method involves producing engineered stone slabs using traditional methods, then scanning and modifying a reference image of natural stone to create a masking image that aligns with the unique characteristics of each slab, including vein placement and color adjustments, to ensure a cohesive and realistic appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional mixing methods are used to produce engineered stone slabs, then manufacturing efficiency is maintained, but the visual appearance lacks natural, random veining and color patterns
Solution Approach 1:
The patent applies preliminary action by pre-forming veined sections within the mold before pouring the base material. These veined sections are created in advance with realistic natural stone patterns, and then the base material is poured around them during the normal manufacturing process. This allows complex veining patterns to be incorporated without requiring complex mixing or post-processing operations.
Solution Approach 2:
The patent uses veined sections as intermediary elements that mediate between the simple mixing process and the desired complex visual appearance. These sections act as physical templates or inserts that carry the realistic veining patterns into the final product, bridging the gap between manufacturing simplicity and aesthetic complexity.
2Manufacturing precision
If digital printing methods are used to add veining patterns, then visual detail is improved, but the veining appears only on the surface rather than throughout the body of the slab
Solution Approach 1:
The patent applies local quality by creating veined sections with specific visual characteristics that are embedded into localized areas of the mold. Each veined section has its own unique pattern and color properties that are preserved when the base material is poured around it. This ensures that the veining appears as an integrated three-dimensional feature throughout the slab thickness, rather than as a surface-only print.
3Productivity
If molds with fixed veining patterns are used, then production speed is maintained, but each slab lacks unique characteristics and gradual color transitions
Solution Approach 1:
The patent applies dynamics by making the veined sections removable and repositionable within the mold. Rather than being fixed permanently in one position, the veined sections can be moved to different locations and orientations for each slab production run. This allows the same veining patterns to be reused (maintaining productivity) while creating different arrangements that give each slab unique characteristics.
Data Source
AI summary
Obtaining a reference image of a natural stone; producing a first engineered stone slab which approximates an aspect of the reference image of the natural stone; performing an examination of the first engineered stone slab; using the reference image and results of the examination, to create a first masking image; and printing the first masking image onto the first engineered stone slab. Producing a second engineered stone slab which approximates the aspect of the reference image of the natural stone, wherein the first and the second engineered stone slabs provide different approximations, as caused by random variation in a manufacturing process; performing an examination of the second engineered stone slab to obtain results; using the reference image and results of the examination of the second engineered stone slab, to create a second masking image; and printing the second masking image onto the second engineered stone slab.