Prefabricated Room Surface Plates for Precise Leveling and Drainage
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Solution Overview
Problem
Existing methods for covering inner surfaces of rooms, such as floors and walls, are labor-intensive, require significant manual effort, and result in inconsistent quality due to dependence on operator skill, leading to physical strain and occupational injuries, with difficulty in achieving precise leveling and drainage slopes without rework.
Innovation Solution
A system and method utilizing pre-fabricated plates or boards that are 3D scanned and CAD/CAM manufactured to fit specific room surfaces, allowing for precise leveling and drainage slope creation, reducing operator burden and improving reproducibility through digital representation and manufacturing of tailored plates for efficient installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual putty application and leveling is performed, then the surface can be covered, but the work requires long experience and training to achieve consistent quality
Solution Approach 1:
The system segments the leveling task into discrete digital steps: 3D scanning of the surface, CAD modeling of the desired final surface, automatic calculation of plate thickness variations, and CAM-controlled manufacturing. This breaks down the complex manual skill into programmable operations that can be executed with consistent precision.
Solution Approach 2:
The patent replaces manual mechanical leveling operations with automated digital systems. The 3D scanner captures surface geometry, the CAD software computes the required plate configurations, and the CAM-controlled machine manufactures the plates with precise thickness variations, eliminating dependence on operator skill and experience.
2Ease of repair
If manual putty work is performed, then surface coverage is achieved, but corrections of wrongly sloping surfaces are very difficult without redoing the work
Solution Approach 1:
The system performs preliminary digital planning and calculation before manufacturing. The CAD software simulates the final surface outcome and allows virtual adjustments to plate configurations before any physical work begins. This preliminary digital prototyping prevents errors from carrying over to the physical installation phase.
Solution Approach 2:
The 3D scanner provides feedback on the actual surface geometry, which is fed into the CAD system to adjust the plate design accordingly. This closed-loop feedback ensures that the manufactured plates will achieve the desired slope and leveling, eliminating the need for post-installation corrections.
3Manufacturing precision
If pre-fabricated plates are manufactured using CAD/CAM, then manufacturing precision is improved, but the device complexity and initial setup increase
Solution Approach 1:
The system creates a digital copy (3D scan) of the physical surface, then generates a digital model (CAD) of the desired outcome. These digital copies allow for precise calculation and simulation before any physical manufacturing occurs, enabling high precision without requiring complex physical jigs or fixtures.
Solution Approach 2:
The CAD/CAM system serves multiple functions: it scans and captures surface geometry, computes plate thickness variations, generates manufacturing instructions, and simulates the final result. This multi-functional software platform consolidates what would otherwise require multiple separate tools and processes.
4Ease of operation
If heavy putty materials are carried manually, then the work can be performed, but operators experience physical strain and occupational injuries
Solution Approach 1:
The system segments the heavy putty material into numerous individual plates of manageable size and weight. Each plate is manufactured to precise specifications, eliminating the need to carry and manually manipulate large quantities of heavy wet putty, thereby reducing physical strain on operators.
Data Source
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AI summary
The present invention relates to a system (10) and method for coverage of at least a part of an inner surface (2) of a room (1) by means of a plurality of pre-fabricated and laid out plates (20).