Wood Flooring Defect Blasting for Precise Particle Removal
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Solution Overview
Problem
Existing methods for removing imperfections from wood flooring boards, such as bark fragments, are inefficient and prone to material waste, especially in industrial settings, due to manual techniques and the risk of sandblasting leaving residues on the wood.
Innovation Solution
An automated system using an artificial vision system and a computer-controlled blasting station with a nozzle, employing media like shredded nut shells, to precisely remove imperfections by generating customized blasting paths based on defect shape and position, ensuring efficient particle removal without damaging the surrounding wood.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual particle removal is performed by trained technicians using a blade or hook, then loose particles can be removed from the defect, but the process is time consuming and has significant variability in quality
Solution Approach 1:
The patent replaces the manual mechanical system (technicians using blades or hooks) with an automated mechanical blasting system. The blasting apparatus uses a controlled stream of abrasive particles to remove loose material from defects, providing consistent results without manual intervention. This substitution eliminates the variability inherent in manual operations while maintaining effective particle removal.
Solution Approach 2:
The blasting system is designed to automatically identify and treat defects without requiring skilled human operators. The system self-regulates the blasting parameters and media selection based on the specific defect characteristics, making the process independent of technician skill level and significantly reducing processing time.
2Reliability
If sandblasting is used to remove particles, then particle removal is effective, but sand particles may remain in the wood board/defect and sandblasting may affect surrounding portions of the board
Solution Approach 1:
The patent employs biodegradable organic blasting media such as walnut shells, corn cobs, or almond shells instead of reusable sand. These materials are designed to be single-use or limited-use, breaking down into fine dust that can be easily removed from the wood grain without leaving harmful residues. The media is discarded after use, eliminating contamination issues.
Solution Approach 2:
The blasting system is precisely controlled to apply the abrasive media only to the specific defect areas identified by the imaging system. The nozzle positioning and media flow are localized to the defect boundaries, preventing damage to surrounding wood surfaces while maintaining effective particle removal from the defect itself.
3Ease of manufacture
If wood filler is applied over loose or removable particles, then the defect can be filled, but the wood filler may loosen or detach during sanding or coarse brushing
Solution Approach 1:
The blasting process is performed as a preliminary step before wood filler application. This pre-treatment removes all loose and removable particles from the defect, creating a stable, solid substrate. By preparing the surface in advance through controlled blasting, the subsequent wood filler application achieves reliable adhesion and prevents loosening during later sanding or brushing operations.
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 system effectively increases the quality grade of wood flooring boards by accurately removing imperfections, reducing material waste, and maintaining the wood's integrity, making the process more viable economically in industrial production.
Implementation Method 1
blasting the defect with a blasting media to remove particles from the defect
Data Source
AI summary
The method can include obtaining a digital image of a wood board having a defect, the digital image including a representation of the defect; using a computer: mapping the position and shape of the representation of the defect, and generating blasting instructions based on the mapped position and shape; positioning the wood board in a given position in a cleaning station, the cleaning station having a blasting nozzle and holding the wood board in its coordinate system; and the cleaning station automatically moving the blasting nozzle relative to the wood board and blasting the defect based on the blasting instructions, including moving at least one of the blasting nozzle and the wood board relative to a frame of the cleaning station.