Decorative Laminate Panel Positioning Code for Straight Cutting
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Solution Overview
Problem
Current methods for manufacturing decorative laminate panels using inkjet technology face challenges in producing personalized images that cover multiple panels efficiently and cost-effectively, leading to assembly complexities and delivery issues due to staggered panel arrangements and cutting errors.
Innovation Solution
A method involving the use of positioning codes on the backside of decorative laminate panels for efficient assembly, combined with inkjet printing of non-staggered digital layouts to allow straight cutting, and inclusion of customer details or identification codes for timely and accurate delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If staggered arrangement of decorative laminate panels is used for sturdy floor assembly, then structural stability is improved, but image distortion occurs during assembly and manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-calculating and pre-arranging the layout of decorative laminate panels in a non-staggered configuration before manufacturing. The system digitally plans the entire floor covering layout, assigning specific panel positions and orientations in advance, which eliminates assembly complexity while maintaining structural stability through the pre-determined optimal arrangement.
Solution Approach 2:
The patent uses digital copying by creating a virtual model of the floor layout that replicates the desired final arrangement. This digital copy allows for precise planning of panel positions, cutting patterns, and orientations before actual manufacturing, enabling complex staggered arrangements to be achieved with simple straight cutting without image distortion.
2Adaptability or versatility
If personalized images covering multiple panels are manufactured using traditional methods, then customization capability is improved, but production cost increases and delivery efficiency decreases
Solution Approach 1:
The patent replaces traditional mechanical printing and assembly systems with a digital-based system. Instead of using complex mechanical processes to create personalized images across multiple panels, the system uses digital imaging, computer-aided design (CAD), and precise digital cutting technology. This substitution enables cost-effective customization while improving delivery efficiency through streamlined manufacturing and just-in-time production capabilities.
Solution Approach 2:
The patent applies parameter changes by dynamically adjusting manufacturing parameters based on customer specifications. The system can modify image dimensions, panel orientations, cutting patterns, and material selections through software parameters rather than requiring physical reconfiguration of equipment. This enables rapid customization at low cost while maintaining high productivity and efficient delivery schedules.
3Manufacturing precision
If straight cutting lines are used for manufacturing decorative laminate panels, then manufacturing precision is improved, but image coverage across multiple panels becomes distorted
Solution Approach 1:
The patent resolves this contradiction by adding the dimension of digital design and virtual planning to the manufacturing process. Instead of trying to achieve image integrity through complex physical cutting patterns, the system uses digital modeling to pre-calculate how straight cuts will affect the final image layout across multiple panels. This allows manufacturers to maintain precise straight cutting while achieving undistorted image coverage through intelligent digital arrangement of panels in the floor layout.
4Productivity
If small personalized orders are processed through mass production systems, then production efficiency is maintained, but order accuracy decreases and delivery errors increase
Solution Approach 1:
The patent implements feedback mechanisms through digital tracking and verification systems. Each personalized order is registered in a digital system that tracks it through all manufacturing stages. The system provides feedback at each step - from order reception and digital design approval to manufacturing completion and delivery verification. This feedback loop ensures that small personalized orders maintain the same accuracy and reliability as mass production, eliminating delivery errors while preserving production efficiency.
Data Source
Figure 1~1D
Figure 2~3A
Figure 3B~3C
AI summary
A method for manufacturing a personalized or customized decorative surface (103) having decorative laminate panels (119) including the steps of: segmenting a digital image of the personalized or customized decorative surface (103) into a plurality of decorative laminate panel images (108), wherein each decorative laminate panel image (108) is sized to fit on a decorative laminate panel (119); assigning a positioning code (109) to a decorative laminate panel image (108) for identifying its position in the digital image of the personalized or customized decorative surface (103); creating a non-staggered digital layout (110) of the plurality of decorative laminate panel images (108); inkjet printing the non-staggered digital layout (110) on a substrate (112); heat pressing the inkjet printed substrate with a protective layer (115) into a decorative laminate (113); dividing the decorative laminate (113) into decorative laminate panels (119), wherein the front side of a decorative laminate panel (119) includes one of the plurality of inkjet printed decorative laminate panel images (108) and the back-side of decorative laminate panel (119) includes the positioning code (109) of the decorative laminate panel image (108) inkjet printed on the front side of the decorative laminate panel (119).