Engineered Stone Surface Printing for Reproducible Décor
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Solution Overview
Problem
Existing methods for manufacturing engineered stones struggle to produce stones with reproducible and predefined décor, and existing equipment for creating chromatic effects in engineered stones lacks high-quality resolution and flexibility.
Innovation Solution
A method involving the steps of providing a mixture of stone or stone-like material and a binder, compacting the mixture, curing the binder, and printing a predetermined décor on the engineered stone's surface, using digital printing techniques to achieve high-resolution and versatile designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If coloring agents are added to the mixture before deposition to create veined effects, then the engineered stone includes chromatic decoration, but the décor is not reproducible and predefined with high resolution
Solution Approach 1:
The patent applies preliminary action by printing the décor pattern on the engineered stone surface after the stone material and binder are deposited and cured. This allows the décor to be applied in a controlled, predefined manner with high resolution, rather than attempting to mix coloring agents into the bulk material where control is lost during deposition and vibration processes
Solution Approach 2:
The patent replaces the mechanical mixing and distribution of coloring agents (which results in uncontrolled veining) with a printing system that deposits pigment or ink directly onto the cured stone surface. This substitution of the decoration application method enables precise, reproducible, high-resolution décor while maintaining the integrity of the stone composite structure
2Reliability
If natural stone is extracted from mines and cut to shape, then building materials with natural décor are obtained, but production costs are high and environmental impact is significant
Solution Approach 1:
The patent applies copying by using printing technology to reproduce natural stone décor patterns on engineered stone surfaces. Instead of extracting and processing natural stone, the invention creates composite materials with printed decorations that replicate the appearance of natural stone veining and patterns, thereby eliminating the environmental harm and high costs associated with mine extraction while maintaining the aesthetic authenticity of natural décor
Solution Approach 2:
The patent uses composite materials by combining stone or stone-like particles with a binder to create engineered stone that can be decorated with printed patterns. This composite approach allows the material to be manufactured without mining, reducing environmental impact and cost, while the printed décor provides the authentic natural stone appearance
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the production of engineered stones with a wide variety of reproducible and predefined décor, achieving higher resolution and more realistic designs, while reducing environmental impact and production costs.
Implementation Method 1
bonded by means of a cured binder like for example resin or cement
Implementation Method 2
bonded together by means of a cured binder such that it is cured at low temperature
Implementation Method 3
press the mixture applying vacuum, with the accompanying application of a vibratory motion at pre-established frequency
Implementation Method 4
press the mixture applying vacuum
Data Source
AI summary
A method for manufacturing an engineered stone, the method including: providing a mixture comprising at least a stone or stone like material and a binder; compacting the mixture; curing the binder; and further comprising printing a printed pattern on at least a top surface of the engineered stone.