Material Board Structured Colored Surface Production
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Solution Overview
Problem
Existing methods for producing material boards with structured, colored surfaces require precise synchronization of structuring and coloring, which is time-consuming and challenging, especially when mimicking natural patterns like wood or stone.
Innovation Solution
A method involving separate image data sets for structuring and coloring, where the structuring information is encoded in one image data set and coloring information in another, allowing for decoupling of the processes to achieve a material board with a structured, colored surface that matches the original pattern with reduced precision requirements during pressing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precise synchronization is used during pressing to match structure and color, then the appearance quality is improved, but the production time and process complexity increase
Solution Approach 1:
The patent divides the original image data into two separate data sets: first image data for structure/relief information and second image data for color information. This segmentation allows the pressing process and coloring process to be decoupled, enabling independent optimization of each process without requiring precise synchronization between them, thus reducing production time while maintaining appearance quality.
Solution Approach 2:
The patent applies preliminary action by pre-processing the image data into separate structure and color components before the pressing process. The structured pressing surface is prepared in advance based on the first image data set, and the colored surface is prepared based on the second image data set, allowing both to be processed independently and combined without requiring real-time synchronization during pressing.
2Manufacturing precision
If precise synchronization is used during pressing to match structure and color, then the appearance quality is improved, but the process complexity increases
Solution Approach 1:
The patent segments the complex pressing and coloring process into two independent processes: a pressing process that uses only the first image data set for structure creation, and a coloring process that uses only the second image data set for color application. This segmentation eliminates the need for complex synchronization mechanisms and reduces overall process complexity while maintaining high appearance quality.
Solution Approach 2:
The patent extracts the color information from the structure information by separating the original image data into distinct first and second image data sets. This extraction allows the coloring process to be completely independent from the pressing process, eliminating the complexity of coordinating both processes simultaneously while ensuring the colored surface matches the structured surface.
3Productivity
If separate image data sets are used for structuring and coloring, then production speed is improved, but the requirement for data processing complexity increases
Solution Approach 1:
The patent performs preliminary data processing by dividing the original image data into first and second image data sets before production begins. This pre-separation of structure and color information enables both pressing and coloring to proceed in parallel without requiring complex real-time data coordination, thus increasing production speed while keeping the actual manufacturing processes simple.
Data Source
AI summary
A method for producing a material board, which has a structured, colored surface, assigns image data to a colored digital image of a colored original surface. The image data is used to produce a first image data set and at least one second image data set, which are each assigned to different color channels of the colored digital image. A colored surface is produced on a base carrier using the at least one second image data set but without using the first image data set. The colored surface of the base carrier is pressed by use of a structured pressing surface of a pressing tool, in order to obtain the material board with the structured, colored surface. The structured pressing surface is assigned to the first image data set.