Engineered Stone Vein Pattern Thermal Transfer
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Solution Overview
Problem
The manufacturing process of engineered stone slabs often results in errors in vein patterns due to variability among operators, making it difficult to produce realistic slabs consistently.
Innovation Solution
A method involving the use of a photo of a natural stone slab to design a stone mold with reference points, aligning a vein pattern printed on paper with alignment marks on the stone slab, and applying a thermal transfer process using weather-resistant ink to achieve accurate and realistic vein patterns on the engineered stone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manual manufacturing methods are used for engineered stone slabs, then operators can apply their skills and experience, but errors in vein patterns occur due to variability among operators
Solution Approach 1:
The patent uses full-body digital photography to capture the complete vein pattern of natural stone slabs, creating a digital template that is then transferred to engineered stone slabs through thermal transfer printing. This copying process eliminates manual drawing errors and ensures consistent reproduction of authentic vein patterns across multiple slabs.
Solution Approach 2:
The patent replaces the manual mechanical process of operators drawing vein patterns with an automated thermal transfer printing system. The system uses heat to transfer ink from a printed template to the engineered stone surface, eliminating human variability and achieving precise, consistent vein pattern reproduction.
2Manufacturing precision
If complex manufacturing processes are used to achieve realistic vein patterns, then production quality improves, but process complexity increases leading to more errors
Solution Approach 1:
The patent performs preliminary actions by capturing the complete vein pattern through full-body photography before manufacturing begins. The digital template is prepared in advance with precise positioning markers, allowing the actual production to proceed through a simpler, more straightforward thermal transfer process rather than requiring complex real-time manual drawing operations.
Solution Approach 2:
The patent introduces a digital intermediate template as a mediator between the natural stone reference and the final engineered stone product. This template, created through photography and digital processing, simplifies the manufacturing process by providing a ready-to-transfer pattern that eliminates the need for complex manual operations during production.
3Quantity of substance
If standard printing inks are used on engineered stone, then production cost is lower, but color fading and discoloration occur over time
Solution Approach 1:
The patent changes the chemical parameters of the ink by using specialized thermal transfer ink formulated for stone surfaces. This ink contains pigments and binders specifically designed to resist fading and discoloration when exposed to environmental conditions, while still allowing thermal transfer onto the engineered stone. The ink formulation balances cost-effectiveness with long-term color durability.
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
This method ensures stable and simple production of realistic engineered stone slabs with accurate vein patterns, reducing labor costs and preventing color fading or discoloration, as the ink penetrates deeply into the stone and adheres well due to its composition.
Implementation Method 1
A thermal transfer process is performed to transfer the vein pattern to the front surface of the full-body stone slab
Implementation Method 2
the ink penetrates deeply into the stone and adheres well due to its composition
Data Source
AI summary
In the present disclosure, an engineered stone is provided. The engineered stone includes a first full-body stone pattern, a second full-body stone pattern and a printed stone pattern. The first full-body stone pattern includes a first stone formulation. The second full-body stone pattern includes a second stone formulation, and the second stone formulation is different from the first stone formulation, wherein the first full-body stone pattern and the second full-body stone pattern are located on a front surface, a plurality of side surfaces and a back surface opposite to the front surface of the engineered stone. The printed stone pattern is located on the front surface of the engineered stone, and the printed stone pattern is overlapped with the first full-body stone pattern and the second full-body stone pattern.