Patent Application
20100043314
The present invention relates to laser-marked multi-component assemblies, laser-marked components, component assembly kits, and methods of laser-marking and assembling the components to form laser-marked multi-component assemblies such as building structures.
Large assemblies such as building structures often present expansive viewable surface areas that may serve as a canvas for application of a graphic design. Graphic designs include patterns, non-patterns, discrete graphic elements, and the like. These graphic designs can be applied to an assembly such as a building structure (e.g., floors, doors, and walls) and non-building structure for creating an ornamental design appearance or providing instructional or other information on the surface. Painting and engraving are just a few examples of techniques that may be employed to apply a graphic design to a large assembly. Engraving may involve carving, cutting, or etching the surface of the assembly components to permanently remove surface area material of the components. Laser etching is particularly useful for creating intricate and high quality finish graphic designs.
One of the difficulties involved in laser marking a graphic design on a multi-component structure post-assembly is that laser marking equipment is typically not capable of handling and marking over the large expansive surface of an assembled multi-component structure, such as floor and wall surfaces. Poor efficiency is another difficulty that arises when attempting to laser mark the expansive surface of an assembled multi-component structure. Still another difficulty involved in laser making an expansive surface of an assembled multi-component structure is difficulty in compensating for seams or spacing between components, such as in the case of seams between adjacent wall panels or spacing between deck planks.
A first aspect of the invention provides a method of laser marking a graphic design in an unassembled multi-component structure. According to this aspect, a graphic design to be laser marked in a multi-component structure is partitioned into a plurality of graphic design sections, with each of the graphic design sections being assigned to a corresponding component of the multi-component structure. The graphic design sections are laser marked in their corresponding components of the multi-component structure while the multi-component structure is in an unassembled state. The laser-marked components are adapted for assembly together into an assembled state in which the multi-component structure has a viewable expansive surface with the graphic design sections collectively simulating an overall appearance of a graphic design spanning across the corresponding components of the multi-component structure.
According to a second aspect of the invention, a method of laser marking a graphic design in components of an unassembled multi-component structure and assembling the components into the multi-component structure is provided. According to this aspect, a graphic design to be laser marked in a multi-component structure is partitioned into a plurality of graphic design sections, with each of the graphic design sections being assigned to a corresponding component of the multi-component structure. The graphic design sections are laser marked in their corresponding components of the multi-component structure while the multi-component structure is in an unassembled state. The laser-marked components are assembled together into an assembled state in which the multi-component structure has a viewable expansive surface with the graphic design sections collectively simulating an overall appearance of a graphic design spanning across the corresponding components of the multi-component structure.
A third aspect of the invention provides a construction kit for a multi-component structure. The kit includes a plurality of components of the multi-component structure in an unassembled state, the components being adapted to be assembled together in an assembled state to collectively establish a viewable expansive surface. Laser-marked graphic design sections are each laser marked in a corresponding component of the plurality of components in the unassembled state. When the components of the kit are assembled into the assembled state, the graphic design sections of the laser-marked components collectively simulate on the viewable expansive surface an overall appearance of the graphic design spanning across the corresponding components.
These and other aspects of the invention, including apparatus, systems, methods, articles, structures, kits, and the like which constitute part of the invention, will become more apparent upon reading the following detailed description of the exemplary embodiments and viewing the drawings.
The accompanying drawings are incorporated in and constitute a part of the specification. The drawings, together with the general description given above and the detailed description of the preferred embodiments and methods given below, serve to explain the principles of the invention. In such drawings:
Reference will now be made in detail to exemplary embodiments and methods of the invention as illustrated in the accompanying drawings, in which like reference characters designate like or corresponding parts throughout the drawings. It should be noted, however, that the invention in its broader aspects is not limited to the specific details, representative devices and methods, and illustrative examples shown and described in this section in connection with the exemplary embodiments and methods. The invention according to its various aspects is particularly pointed out and distinctly claimed in the attached claims read in view of this specification, and appropriate equivalents.
The term “laser mark” used herein means to irradiate a component, such as a PVC-wood composite, with a laser beam to form a graphic design. In the course of marking, the laser beam causes a visually perceptible change to the component surface. The change may involve removal, ablation, etching, engraving, or change of color of a coating or the body of the component. The result is a visually-perceptible graphic mark in the component. As used herein, “in the component” includes laser marking the surface of the component without necessarily engraving into the surface.
The terms graphic and graphic design include decorative and artistic designs, non-decorative designs, patterns, graphic images, wood grain, alpha-numeric characters, corporate and trade logos, other identification.
The term “components” as used herein includes but is not necessarily limited to building components. Building components include, for example and not necessarily by limitation, flooring, decking, wall panels, door panels, door trim, siding, cabinetry, railings, etc. for residential and commercial buildings. For explanatory purposes, exemplary embodiments below are described in relation to building components and assembled building structures. It should be understood that the methods and systems described herein and the following exemplary embodiments may be used for marking components other than building components, such as furniture, automotive and packaging components.
Examples of materials that may be treated using the systems and methods embodied herein include glass (tempered glass and/or annealed glass), stone, ceramic, granite, engineered wood, laminates, metal, plastic, gypsum, fiberglass reinforced plastic, wood composites, vinyl, acrylic, polyvinylchloride, hardboard, veneer, low profile carpet tiles, fabrics, paper, etc. For example, U.S. Pat. Nos. 5,486,553 and 5,539,027, both entitled “Advanced Polymer/Wood Composite Structural Member” to Deaner et al. disclose a polymer-wood composite that may be selected for the components. The component members are formed from a composite containing, for example, 30 to 50 wt % of sawdust along with 50 to 70 wt % of a polyvinylchloride (PVC) polymer.
A system for marking components such as building structure components using a high-speed, high-power laser is shown in
The system includes a controller, designated by reference numeral 30 in
The laser beam 12 is deflected by the y-axis mirror 17 and directed through a focusing lens 19 adapted to focus the laser beam 12. The lens 19 may be a multi-element flat-field focusing lens assembly, which optically maintains the focused spot on a flat plane as the laser beam 12 moves across a work piece/component 21 to laser mark a graphic. The lens 19, the mirrors 13, 17 and the galvanometers 14, 18 can be housed in a galvanometer block (not shown).
The apparatus 10 further includes a working surface 20 which can be a solid support such as a table, or even a fluidized bed. The work piece (such as a building component) 21 is placed on the working surface 20. The work piece 21 includes a viewable, laser-markable surface 22 to be laser marked. The working surface 20 can be adjusted vertically to adjust the distance from the lens 19 to the laser-markable surface 22 of the work piece 21. The laser beam 12 is directed by the mirrors 13, 17 against the laser-markable surface 22 of the work piece 21. Usually the laser beam 12 is directed generally perpendicular to the laser-markable surface 22, but different graphics can be achieved by adjusting the angle between the laser beam 12 and the laser-markable surface 22, for example, from about 45° to about 135°. Relative movement between the laser beam 12 and the laser-markable surface 22 of the work piece 21 causes a graphic 23 to be marked in the laser-markable surface 22. The movements and timing of the mirrors 13, 17 and the power of the laser beam 12 are controlled by the numerical control computer 15 to mark the specific desired graphic 23. As referred to herein, relative movement may involve movement of the laser beam 12 (e.g., using the mirror system) as the work piece 21 remains stationary, movement of the work piece 21 while the laser beam 12 remains stationary, or a combination of simultaneous movement of the laser beam 12 and the work piece 21 in different directions and/or at different speeds.
A second computer such as a work station computer (31 in
According to an implementation, the graphic design to be laser marked in the components may be created using Adobes® Illustrator, or any similar vector based rendering program. Generally, the features that may be etched using vector-based programs include lines and curves that define the outlines of the graphic and its major linear and curved features. The vector-based rendering program AutoCAD® developed by AutoDesk®, Inc. may be employed for this task. In order to make special features such as contour fills that are either difficult or impossible to prepare with AutoCAD®, the additional vector-based program Cutting Shop of Arbor Image Corp. may be used. Cutting Shop is a commercially available product of Arbor Image Corp. promoted for cutting and engraving applications. The raster-based program Technoblast® from Technolines LLC can create computer readable instructions for controlling the laser path and power for marking certain features. The raster- and vector-based program Exodus may be used to rip the files received TechnoBlast® programs into a .tbf graphic (raster) file for the laser controller. Lasers are typically equipped with appropriate software to convert computer files into the laser manufacturer's language.
According to an implementation, a graphic image is scanned or otherwise input into the work station computer, converted into the proper format, e.g., digitized, and digital information corresponding to the lased features of the graphic image is introduced into the control computer with instructions to laser mark graphic design sections into their corresponding elements. The control computer controls movement of the galvanometers 14, 18 and associated mirrors 13, 17 and the power output of the laser 11 to mark the first graphic element on the working surface of the work piece 21 at the appropriate power, movement velocity for high throughput, and beam spot site. At the same time, controllers and the workstation coordinate the relative movement and output of the laser with the article on the support 20. The laser controller will also control transverse movement of the laser beam. The power, beam size, and scan speeds may be selected depending upon the work piece material and intricacy of the graphic design. It may be preferable to avoid undesirable consequences of over-treatment, such as complete carbonization, burn-through and/or melting of the work piece, or under-treatment where the graphic image is not visible or only partially visible. The system can also include a tank 24 to inject a gas such as an inert gas into the working zone for cooling purposes. The amount of gas can be controlled by the work station computer 26, 31, laser controller, or other apparatus.
The work station computer 26, 31 may be, for example, a personal computer system. Computer hardware and software for carrying out the embodiments of the invention described herein may be any kind, e.g., either general purpose, or some specific purpose such as a workstation. The computer may be a Pentium® class or multi-core processor computer, running for example Windows XP®, Windows Vista®, or Linux®, or may be a Macintosh® computer. The computer may also be a handheld computer, such as a PDA, cellphone, or laptop. The programs may be written in C, or Java, Brew or any other programming language. The programs may be resident on a storage medium, e.g., magnetic or optical, of, e.g., the computer hard drive, a removable disk or media such as a memory stick or SD media, or other removable medium. The programs may also be run over a network, for example, with a server or other machine sending signals to one or more local machines, which allows the local machine(s) to carry out the operations described herein.
It should be understood that methods of the present invention may be carried out using various other laser systems having alternative layouts and components to those shown in
Referring now more particularly to the flowchart of
The surface area configuration and dimensions of the components are determined and likewise input into the work station computer 26, 31. The multi-component structure 70 of
Where it is predetermined that all of the components 71-79 are identical to one another (except for the design sections lased on the components), as in
The multi-component structure of
From the above description, it will be understood that certain exemplary embodiments of the invention feature the marking of individual component elements of product structures such as decking, railings, and flooring materials (and other products outside the building industry) with design graphics that are made up of individual graphic elements laser engraved or otherwise laser marked in the component in such a way that the graphic pattern is viewable, spanning across adjacent components, when several or all of the components are assembled in a pre-determined arrangement, e.g., an array. The graphic design sections of the marked components may collectively form a cohesive design having the appearance of continuously extending across adjacent components, so that the graphic design sections collectively produce an interconnected and unified aggregate image spanning multiple components of the structure. The aggregate graphic may represent a pattern that is repeating such as a diamond, houndstooth or chevron pattern, for example, or may represent a non-repeating pattern that is organic, floral and/or natural in such a way that it does not repeat. The patterns and graphics may be as simple as geometric designs or highly complex. The inventive concept may permit the laser marking of advanced, highly aesthetic designs to allow manufacturers to offer premium products not now available in the marketplace.
The foregoing detailed description of the certain exemplary embodiments of the invention has been provided for the purpose of explaining the principles of the invention and its practical application, thereby enabling others skilled in the art to understand the invention for various embodiments and with various modifications as are suited to the particular use contemplated. This description is not intended to be exhaustive or to limit the invention to the precise embodiments disclosed. Although only a few embodiments have been disclosed in detail above, other embodiments are possible and the inventors intend these to be encompassed within this specification and the scope of the appended claims. The specification describes specific examples to accomplish a more general goal that may be accomplished in another way. Modifications and equivalents will be apparent to practitioners skilled in this art and are encompassed within the spirit and scope of the appended claims and their appropriate equivalents. This disclosure is intended to be exemplary, and the claims are intended to cover any modification or alternative which might be predictable to a person having ordinary skill in the art.
Only those claims which use the words “means for” are to be interpreted under 35 USC 112, sixth paragraph. Moreover, no limitations from the specification are to be read into any claims, unless those limitations are expressly included in the claims.
This application claims the benefit of priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 61/090,796 filed Aug. 21, 2008 entitled “Laser-Marked Multi-Component Assemblies, Kits, and Related Methods,” the complete disclosure of which is incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61090796 | Aug 2008 | US |
