Laser-Cut Laminate Structure for 3D Visual Relief
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Solution Overview
Problem
Existing methods for manufacturing laminated products, such as photo albums and decorative elements, are time-consuming, costly, and limited by artisanal steps and the lack of versatility, failing to achieve a three-dimensional visual effect.
Innovation Solution
A laminated product comprising two elements with different thermal characteristics, where a polymeric first element with a lower melting point is coupled to a cellulosic second element with a higher flash point, using an adhesion layer, and processed using laser cutting to create a three-dimensional visual effect by varying the power and speed of laser beams in specific angles and movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If artisanal or manual steps are used to manufacture laminated products, then customization and personalization are achieved, but time expenditure and cost increase significantly
Solution Approach 1:
The patent replaces manual mechanical assembly operations with automated laser processing. The laser system automatically performs cutting, melting, and adhesion layer application based on digital designs, eliminating the need for artisanal manual steps while maintaining customization capability through software-controlled parameters.
Solution Approach 2:
The invention utilizes changes in material parameters (melting point differences between polymeric and cellulosic layers) to enable automated processing. By controlling laser power and speed parameters, the system selectively melts or cuts specific layers without manual intervention, achieving both automation and customization.
2Adaptability or versatility
If artisanal methods are used for laminated product manufacturing, then personalized products are obtained, but material and tool costs increase
Solution Approach 1:
The laser processing system serves multiple functions (cutting, melting, adhesion application) using a single tool, eliminating the need for multiple specialized artisanal tools. This universal approach reduces tool costs while maintaining the ability to create personalized products through software control.
Solution Approach 2:
The patent employs digital design files and software templates that can be easily modified and reused, replacing expensive physical molds or custom tooling. The digital assets have negligible reproduction costs and can be adapted indefinitely for different personalized products.
3Manufacturing precision
If dedicated printers and molds are used, then specific product variations are achieved, but versatility and reuse possibilities decrease
Solution Approach 1:
The system transitions from static dedicated molds to dynamic software-controlled laser parameters. By adjusting laser power, speed, and path digitally, the same equipment can precisely produce different product variations without physical reconfiguration, maintaining manufacturing precision while maximizing versatility.
Solution Approach 2:
The invention separates the design specification from the manufacturing process. Digital design files contain all product variation information, allowing infinite customization without requiring dedicated physical tools for each variation. The laser system executes these digital segments independently, achieving both precision and versatility.
4Ease of operation
If artisanal steps are employed, then manual control is maintained, but the process lacks three-dimensional visual effect capability
Solution Approach 1:
The patent exploits phase transitions (melting and solidification) of the polymeric layer through controlled laser heating. By selectively melting and re-solidifying material, the system creates genuine three-dimensional relief effects that cannot be achieved through manual manipulation alone, while the digital control maintains operational ease.
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
The method enables the production of laminated products with a three-dimensional visual effect without artisanal steps, reducing costs and increasing versatility, suitable for various applications like notebooks and decorative elements.
Implementation Method 1
a first element (100) with a melting point temperature lower than the flash point temperature of the second element (200)
Implementation Method 2
Applying pressure on the assembly formed by the first element (100), adhesion layer(s) (300), and second element (200)
Implementation Method 3
at least one adhesion layer (300) arranged between the first element (100) and the second element (200)
Data Source
AI summary
The present invention relates to a laminated product that comprises at least one first element (100) coupled to at least one second element (200) by means of at least one adhesion layer (300), wherein the first element (100) has a melting point temperature lower than the flash point temperature of the second element (200). The present invention also relates to a method for manufacturing a laminated product (10), a method for processing a laminated product (10) to obtain a cut product (500), the use of a cut product (500), and a computer-readable memory.