BRPI1006807A2 - Marked surface articles, related methods and systems - Google Patents

Abstract

Surface marked articles, methods and related systems A method of marking the surface of an article, especially a construction product, is provided. One described method includes the steps of laser marking a first graphic design element on one surface of an article and inkjet printing a second graphic design element in registration with the first graphic design element on the article surface to create a high quality global graphic design. Articles made in accordance with this method, and systems for carrying out the method are also provided.

Description

Descriptive Report of the Invention Patent for MARKED SURFACE ITEMS, METHODS AND RELATED SYSTEMS. CROSS REFERENCE TO RELATED PATENT APPLICATIONS AND PRIORITY CLAIM

This patent application claims the benefit of U.S. Provisional Patent Application No. 61 / 145,316, entitled Surface Marked Articles and Related Methods and filed on January 16, 2009, hereby incorporated by reference and to which priority is claimed.

FIELD OF THE INVENTION

The present invention relates to articles, especially doors and door coverings, surface marked by laser marking and inkjet printing to provide high quality decorative products. The present invention also relates to methods and systems for making such articles.

BACKGROUND OF THE INVENTION

Residential and commercial construction products are often made from an engineering composite material, including cellulosic composite materials, such as fiber board and high density particle board, as well as other synthetic materials such as laminates, veneers and molding compound of reinforced polyester sheet (SMC), to name a few. Such products find diverse applications, including indoor uses, such as interior passage doors and door coverings, mortar-free walls, countertops, kitchen cabinets, wainscoting, floors, wall panels, ceiling tiles, interior trim components , and exterior uses, such as for entrance doors, adornments, sides, trimmings, fences, and window frames.

Although synthetic materials can provide substantial cost savings over natural materials such as wood, stone and ceramics, synthetic materials do not have the attractive appearance and authenticity of natural materials. For this reason, great efforts have been made to modify the appearance of the surface of synthetic materials, such as engineering composite materials to simulate the beauty and complexity of

2/31 natural materials. Conventional printing technologies, such as inkjet printing, apply ink graphics to the surface of synthetic materials to mimic the general patterns of a naturally occurring material. Synthetic materials with only inkjet graphics, however, may not have sufficient aesthetic appeal for more discriminating consumers.

Inkjet printed surfaces do not have a sense of texture inherent in many natural materials that are vital to their appearance. In addition, cylinder printing and strip overlapping techniques suffer from several problems when they are used on non-uniform surfaces. Non-uniform article surfaces may have particular characteristics, such as channels or recesses, which lie below a main planar surface of the article. Cylinder printing techniques may fail to contact such surface characteristics below the main flat surface. Sheet overlays, on the other hand, can completely hide or hide these characteristics. Other decorative surface processes, such as sandblasting and coating, have their drawbacks, such as high cost.

Laser marking techniques apparently provide an attractive alternative to the above conventional processes for decorative construction products. Generally, laser marking, or laser engraving, is an energetic non-contact process based on the heat generated by a laser beam incident on the surface of a workpiece to change the surface of the workpiece. The output power of the laser, the focal point of the laser beam, and the speed of the laser beam (that is, the travel speed) can be adjusted to manipulate the extent of the change. However, lasers alone continue to be insufficient to generate realistic simulations of natural surfaces, such as wood, stone or other natural materials. Even with the addition of a painted earth covering, on laser-treated surfaces certain standard elements of authentic natural materials are missing, such as wood fibers in the case of wood reproductions, or interlocking mineral grain mosaics

3/31 I walk in the case of natural stone reproductions. Distinguishing between an authentic natural material and a synthetic material, such as medium density fiberboard (MDF) or chipboard treated with a conventional laser remains easy, even from a distance.

In addition, several restrictions create difficulties with the use of conventional lasers to create complex graphics. Due to the relatively limited power capacity of conventional lasers, and the economic expense of lasers operating with high energy outputs, lasers are normally operated at relatively low energy levels to manufacture articles such as construction components. These energy concerns, coupled with the high density of workpieces, such as certain engineered wood compounds, place restrictive limitations on the rate at which the laser beam is able to create a graphic design on the surface of a workpiece synthetic. Creating expansive or particularly complex graphics may require prolonged efforts that make high-capacity manufacturing economically unviable.

SUMMARY OF THE INVENTION

A first aspect of the invention provides a method of marking the surface of an article, such as a door, featuring registering a first graphic design element with a second graphic design element, laser marking the first graphic design element on a surface of the article and a second inkjet graphic design element on the surface of the article, the first and second graphic design elements being registered with each other to provide an overall high quality graphic design that visually and texturally simulates a natural material .

A second aspect of the invention relates to an article with a first laser-marked graphic design element on a surface of the article, and a second inkjet-printed graphic design element in a predetermined orientation or association with the first design element. graphic on the article surface to provide a global high-quality graphic design that visually and texturally simulates a

4/31 natural material.

A third aspect of the invention relates to an article's surface marking system. The system includes a laser marking apparatus and an inkjet printing apparatus for printing first and second graphic design elements, respectively, in a predetermined orientation or association relative to each other to provide a high quality graphic design general that visually and texturally simulates a natural material.

Other aspects of the invention, including devices, systems, methods, and the like that are part of the invention, will become more evident by reading the following detailed description of the exemplary modalities and the visualization of the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are incorporated and form part of the specification. The drawings, together with the general description given above and the detailed description of the exemplary modalities and methods indicated below, serve to explain the principles of the invention. In such drawings:

figure 1 is a flow chart of a method for marking a surface of an article according to an embodiment of the invention;

figure 2 is a flow chart of a method for marking a surface of an article according to another embodiment of the invention;

figure 3 is a vertical projection view of a door frame article according to an embodiment of the invention;

figure 4 is an enlarged fragmentary view of the door frame article of figure 3, according to an embodiment of the invention;

figure 5 is a cross-sectional view taken along the transverse line V-V of figure 3;

figure 6 is a flow chart of a method for marking a surface of an article according to another embodiment of the invention;

figure 7 is a schematic view of a system for marking a surface of an article according to an embodiment of the invention;

figure 8 is a schematic view of a laser and laser controller of the system of figure 7, according to an embodiment of the invention;

figure 9 is a schematic view of an inkjet printing apparatus of the system of figure 7, according to an embodiment of the invention;

figure 0 is a schematic view of a printing station of the printing apparatus of figure 9 according to an embodiment of the invention, and figure 11 is a schematic view of the inkjet printer of figure 9 according to an embodiment of invention.

DETAILED DESCRIPTION OF EXEMPLIFICATIVE MODALITIES AND EXEMPLIFICATIVE METHODS

Reference will now be made in detail to modalities and method. 15 of the examples of the invention, as illustrated in the accompanying drawings, in which equal reference characters designate equal or corresponding parts in all drawings. It should be noted, however, that the invention in its broadest aspects is not limited to specific details, representative devices and methods and illustrative examples shown and described in connection with the exemplary modalities and methods.

In an exemplary embodiment of marked surface articles and related methods, a method is provided in which a first graphic design element is laser marked on a surface of an article and a second graphic design element is printed with a 25-ink jet on the surface of the article. The first graphic design element is registered with the second graphic design element so that the total graphic design can be a cooperative interaction between the laser marked graphic design element and the inkjet printed graphic design element. By orienting the first graphic design element and the second graphic design element in a predetermined orientation or association with respect to each other, the methods of the invention can produce a coordinated appearance of the final graphic design. Spatially, the predetermined orientation or association relative to the first and second graphic design elements may involve its registration, superposition or juxtaposition on the article surface using, for example, predetermined coordinates. Aesthetically, the graphic design elements marked with 5 laser and inkjet printing produce a synergistic effect manifested as a high quality simulation of natural materials that could not be achieved by both laser marking and inkjet printing alone. In certain exemplary embodiments of the first graphic design element the second graphic design element 10 can also produce a texture contrast as discussed below.

Referring now to the drawings, in which equal numerals indicate equal elements across the various figures, figure 1 is a flow chart of a method for marking a surface of an article according to an embodiment of the invention. Items that may be subject to .15 marking in accordance with the present invention include synthetic building components which are intended to replicate natural wood. Especially contemplated are external entrance doors and internal passage doors, wooden floors and floor components, siding, panels, furniture components, etc., whether of solid construction or the so-called hollow-core doors built from a peripheral door frame with opposite door linings. Peripheral door structures include styles and rails that define the sides and top and bottom of the door. A pair of door liners have internal surfaces attached to opposite sides of the peripheral door frame via glue, mechanical fasteners, etc., and opposite external surfaces. As is known in the art, hollow core doors can include additional support members and / or core materials (e.g., foam) disposed between the linings.

Other building components that may be subject to the exemplary methods and systems described in this document include furniture and cabinet doors, cabinet and two-part doors, door trim, window frames, furniture elements, cabinets, moldings

7/31 ras, pictures, molded wall panels, wainscoting, wooden floors, wall panels, siding, railings, window trim, architectural trim, flooring, etc. For explanatory purposes, exemplary modalities regarding construction components, in particular door frames, are described below. It should be understood that the methods and systems described in this document can be used for the marking of construction components and other articles of construction components.

The exemplary methods and methods described here are specially designed for use with engineering composite materials, such as medium density fiber board (MDF) and high density chipboard. Engineered composite materials often contain cellulosic fibers or other particles, often broken in a shredder, and a resin and, optionally, wax, which are compressed at high temperatures and pressures. Cellulose fibers / particles often make up more than 90 percent by weight of the material. The cellulose component is usually, but not necessarily, wood fiber. The bonding resin is typically a thermally fixed material. An example of an engineering composite material is described in U.S. Patent No. 5344484. Examples of other materials that can be treated with the systems and methods embodied in it include glass fiber reinforced composite molding polyesters (SMC), substrate base paints and coatings, polymer sheets, veneers, papers and materials natural, for example, wood.

As shown in figure 1, a first graphic design element is registered with a second graphic design element 102 in a first step. In one embodiment, the first graphic design element can be associated with a first graphic element file, and a second graphic design element can be associated with a second graphic element file. To achieve the predetermined desired orientation or association between the first graphic design element and the second graphic design element, the first graphic design file and the second graphic design file

8/31 can be systematically combined for visual (ie, aesthetic) and tactile (ie, touch) printing to produce one or more unified graphic design files.

The graphic designs mentioned here may include decorative and artistic designs. The graphic design can include simple geometric shapes and / or highly complex artistic representations. The graphic design can include repetitive patterns, such as a diamond, checkered or chevron pattern, or non-repetitive patterns, such as floral designs. Graphic designs that simulate the appearance of wood fiber patterns and features striated or laminated are especially applicable. As discussed in greater detail below, exemplary embodiments of the invention allow the printing and marking of advanced, highly aesthetic graphic designs to allow the manufacture of premium products, including those that are not now available on the market, in an economical way for industrial production high yield.

After the first graphic design element is registered, that is, it reaches a predetermined orientation or association, with the second graphic design element 102, the first graphic design element is laser marked on a surface of an article 104. A printer laser marking (ie a laser printer), comprised of a laser and a laser controller can mark one or more graphic design elements on one or more parts of the article surface. Each graphic element can be associated with a graphic element file.

In the course of laser marking, a laser beam causes a visually noticeable variation to the surface of the article, usually causing removal, ablation, or etching of a coated or uncoated article surface. The visually perceptible variation is typically in the form of a recess of a depth that extends in part through the article or article covering, without cutting entirely through the article. (This is not to dispense with the use of the laser for cutting operations in sepa

9/31 also.) The recess can be configured as a channel, groove or trench, cavity or other depression. Recesses configured as elongated length channels / trenches can be arranged on the surface of the article to create an appearance that the article (for example, door frame) has been grooved, laminated, or assembled together from various elements, ie , as opposed to a monolithic structure.

The laser beam can be configured to create simulations that mimic the touch texture or feel of natural materials and / or traditional processing techniques. For example, the laser beam can be controlled to convey a relatively coarse texture feel to the recessed area that mimics the texture or feel of a processed non-synthetic object, such as streaked or laminated wood that has not been significantly sanded. If the flat surface of the article is relatively smooth before laser marking, that smoothness is maintained in areas of the article surface that are not laser marked, while the surface areas that are laser marked develop a greater roughness due to the marking. laser. The surface topography of coarse areas can be characterized visually (from a naked eye perspective) as irregular and uneven in many cases. Laser marking, especially when applied to MDF, forms a surface that appears to expose the ends of individual wood fibers. The contrast in texture between adjacent surfaces contributes to the highly desirable visual impression of the graphic design and contributes to the overall aesthetic quality of the product.

Laser marking can be done on the substrate of the article, or any layer of an applied finish. The laser marking can partially or completely penetrate any of the layers or the substrate. The depth of the laser marking can vary from a shallow marking on the surface to a complete penetration of the article substrate. In one embodiment, laser marking can penetrate the base coat, but not so much as to enter the substrate. In another embodiment, laser marking penetrates the finish, but not the coating of

10/31 base. In other embodiments, laser marking can penetrate a combination of these and other depths.

Finally, in step 106, the second graphic design element is inkjet printed on the surface of the article. An inkjet printer, comprising one or more inkjet print heads and an inkjet printer driver, can print the second graphic design element on one or more parts of the article surface.

In an exemplary modality, during the course of laser marking an MDF article, the resin and wood fibers of the MDF are removed. The removal creates a depth and simultaneously changes the color of the MDF to a brown tone. When the removed area is printed with inkjet, the combination of laser marking and inkjet printing achieves a synergistic effect with a visual appearance superior to the use of any isolated technique. In addition, areas that are laser marked and coated with ink reflect light differently from areas that are coated with ink, but not laser marked. This contrast increases the perceived depth of the laser-marked areas. The paint can be applied to exposed MDF fibers, which provide an improved visual and tactile effect previously unattainable.

The laser marking and inkjet printing process is not limited by the substrate, and may include articles comprised of MDF / plywood agglomerates, SMC fiberglass polyesters, paints, base coatings on substrates, papers, foils. polymers, sheets, and natural woods.

In various modalities, laser marking and inkjet printing can be carried out in any order or substantially simultaneously. In the embodiment shown in figure 1, a part of the article's surface is first laser marked and then secondly printed by inkjet. Figure 2 is a flow chart of a method for marking a surface of an article according to another embodiment of the invention. As shown in figure 2, the second graphic design element

11/31 is inkjet printed on the surface of article 206 before the first graphic design element is laser marked on the surface of article 208.

As represented by the dashed lines in figure 2, laser marking and inkjet printing of the graphic design elements can be carried out in multiple stages. (The descriptors first and second graphic designs are not intended to indicate the sequence in which graphic designs are created or applied to the surface of the article). The entire surface of the article, or alternatively a part of the surface, can be laser marked. Likewise, the entire surface of the article, or some part of the surface of the article, can receive inkjet printing. In some embodiments, it may be beneficial for the laser marking process to precede inkjet printing, such as where all or part of the second graphic design element is to be inkjet printed over some or all of the first laser marked graphic design element.

As shown in figure 2, after the first graphic design element is registered with the second graphic design element 202, the surface of the article is prepared at 204. In one embodiment, a base coat is applied to all or part of the surface of the article. The base coat, for example, prepares the surface of the article for inkjet printing.

Figure 3 is a vertical projection view of a door frame article according to an embodiment of the invention. Figure 3 comprises a door frame 300. As shown in figure 3, a plurality of channels 308 provides the appearance that the door frame 300 is constructed from a plurality of vertical planks 304a, 304b and a plurality of horizontal planks 306a, 306b. Vertical planks 304 and horizontal planks 306 collectively define a larger flat part 302.

As illustrated in figure 3, channels 308 are configured in rectangular or square outlines (seen in the plane) to define the con-.

12/31 lathes of a plurality of interior panels 310. For the purpose of the present discussion, the entire outer surface of the article around or otherwise peripheral to the interior panels 310 is referred to as the major flat part 302. The outer surfaces of the part major plane 302 and the inner panels 310 can be coplanar with each other. The larger flat part 302 and the inner panels 310 may have smooth outer surfaces, while the areas corresponding to channels 310 may have a coarse outer surface to replicate the texture of striated or laminated wood. The door structure 300 of Figure 3 includes ten (10) of the inner panels 310. The ten inner panels 310 of the illustrated embodiment are square and identical to each other. In other embodiments, a surface article may include one or more inner panels 310. In addition, inner panels 310 may have other shapes, and may be identical or different in shape from one another.

Figure 4 is an enlarged fragmentary view of the door frame article of Figure 3. As shown in Figure 4, channels 308 can be laser engraved in the vicinity and, generally concentric to each other to provide the peripheries of the inner panels 310 with the appearance of wood that has been expertly grooved or subjected to laminating work. In addition to the laser marking of channels, as described above, a variety of other graphics, including intricate and ornate laser design patterns, can be marked on various articles, such as construction products. As an example, the inner panel 308 of the door frame 300 includes a highly complex or ornate design such as a braided rope design 312 laser etched between generally concentric channels 308. It should be understood that other complex designs can be laser marked on the surface of the article. For example, for wood simulations, small depressions on the surface of the article can be created by laser marking. These small depressions can mimic the appearance of wood knots found in natural wood, such as oak or mahogany knots.

Laser marking can be used to create other patterns from

13/31 in addition to wood patterns or laminating work. For example, laser recesses marked on an article surface can be arranged in a grid pattern to simulate the edges of ceramic tiles or bricks on a wall or floor structure, with the channel grid pattern having a marked surface at coarse laser that replicates the appearance of grout or mortar. The texture created by the laser in such channels can be controlled to provide a visual and tactile impression of roughness similar to that of mortar or grout, while the unmarked areas of the product's surface remain smooth to closely simulate the look and feel of a ceramic . In yet another exemplary modality, the recesses can be laser marked along non-linear paths to simulate the edges of uncut natural stone, for example.

A second complementary graphic design element is printed in inkjet with the first laser-marked graphic design element in order to create greater synergy or overall graphic effect. Distinct graphics can be applied to laser-marked and non-laser-marked areas to increase contrast. In the case of a wood simulation, for example, lighter tones and more visible fiber patterns can be inkjet printed on the smooth (ie, non-laser-marked) areas of the article surface than on the rough areas (i.e. laser-marked).

The intricate details of complex designs that may be prohibitively expensive or impractical for laser marking can be inkjet printed on the article surface as a second graphic design element registered with a first laser marked graphic design element. Patterns of wood fibers and tones of oak, walnut, cedar, mahogany and other wood species can be inkjet printed on the article surface to replicate real surface appearances of simulated wood. Even patterns of exotic wood fibers, such as leopard wood fiber patterns and other patterns can be printed with inkjet. Some patterns that may be capable of laser marking, such as the twisted rope design 312, can be inkjet printed to speed up production.

The improved effect of global graphic design reaches a three-dimensionality. Figure 5 is a cross-sectional view taken along the VV cross-section of figure 3. In some cases, due to manufacturing and / or economic restrictions, the recesses formed on an article surface via laser marking are sometimes relatively small. shallow and with a substantial lack of depth. Such shallow recesses alone do not necessarily create a realistic impression of the three-dimensionality typically achieved by streaking and lamination work. It is evident in many cases that the article is an artificial monolithic body with no more than marks on the surface. To give greater dimensionality and realism to the first laser-marked graphic design element, a second graphic-design element is printed in inkjet with the first laser-marked graphic design element on the article surface. In some embodiments, certain inkjet printers can be configured to apply graphic design elements to laser-marked recesses.

In a particular exemplary embodiment of the invention, one or more inkjet printed graphic design elements are designed to create an improved three-dimensional print, such as an illusion (or user perception) that the first laser-marked graphic design element has a depth greater than your greatest real depth. Inkjet printed graphic design elements can simulate shading or lighting for this purpose. To create this three-dimensional effect, the inkjet printed graphic design elements can be applied within the limits of channel 308 or immediately adjacent to channel 308, that is, at the edge of the outer surface of the major flat part 302 and the inner panels 310 .

Advantageously, methods for surface marking of articles with registered graphic design elements can produce articles with highly realistic, ornate appearances, closely replicating the look of more expensive materials such as wood, stone and ceramics. When using such methods, the high costs of specific alternatives, such as fer15 / 31 unique molding and cooling tools for applying a three-dimensional feature to the article become unnecessary.

Figure 6 is a flow chart of a method for marking a surface of an article according to another embodiment of the invention.

The method in figure 6 illustrates a method of using exemplary software for creating a graphic design and converting the graphic design into a computer-readable medium for a laser marker and an inkjet printer. As shown in figure 6, the graphic design is created using the Adobe® llustrator, a 10 602 vector-based rendering program. In various modalities different vector-based rendering programs can be used to create the graphic design. Alternatively, the graphic design can be received from an optical scanner or an optical reader.

The different elements of the graphic design can be selected manually or automatically for laser application and printing, respectively. Such elements may include specific features of the graphic design, such as channels or recesses, colors or tones, or specific sections of the graphic design. In one embodiment, a software program automatically identifies the most suitable resources for any laser marking or inkjet printing, based on predetermined criteria. In another mode, an operator manually identifies or assigns various elements of the graphic design for laser marking or inkjet printing. Characteristics and / or sections of the graphic design designated for laser marking are referred to here as first elements of graphic design, while characteristics and / or sections of the graphic design designated for printing are referred to here as second elements of graphic design. The first and second graphic design elements can be stored together in a unified image file or separately in the respective image files.

In the modality shown in figure 6, the graphic design is divided into a laser graphic template and an inkjet graphic template. The laser graphic template includes the characteristics of the graphic design that will be

16/31 processed using vector-based programs. Generally, the graphic design elements that are laser marked include lines and curves that define the contours of the graphic and their main linear and curved characteristics. One or more vector-based rendering programs can create vector files with such characteristics. Other graphic design elements that can be laser marked include three-dimensional filling characteristics such as gradient outlines and surface textures. Scan-based rendering programs can create one or more scan files with such characteristics. As shown in Figure 6, the AutoCAD® vector-based rendering program developed by AutoDesk®, Inc. creates a 604 vector file. The Arbor Image Cutting Shop vector-based program also creates a vector file with features such as fillers special contour 606. Such contour fillings may be difficult or impossible to prepare with AutoCAD®. The Cutting Shop is a commercially available product from Arbor Image Corp, promoted for cutting and engraving applications. In other modalities, other vector-based programs can be used to create laser-marked graphic design elements.

Referring also to figure 6, Adobe Photoshop® is used to create a raster file containing a grayscale image of three-dimensional fill characteristics such as gradient outlines and surface texture. Adobe Photoshop® can produce a grayscale image file comprising such fill characteristics. From the grayscale image, the Technoblast® scan-based program from Technolines LLC creates computer-readable instructions to control the laser path and power for laser marking of the 608 filling characteristics.

After several vector files are created, the files can be processed, or converted into a form that is understandable by a laser marker or an inkjet printer. The vector and scan-based Exodus program is used to copy files received from the AutoCAD®, Cutting Shop, and Technoblast® 612 programs. Ο

17/31 Exodus program processes the files both in a graphic file (vector)

a.dxf 616 as well as in a graphic file (scan) a.tbf 618 that can be used by the laser marker. Laser and inkjet markers are typically equipped with the appropriate software to convert computer files into the language of the laser and printer manufacturer.

The inkjet graphic mold can represent both the coloring of the graphic design and any filling patterns that are not suitable for vector-based processing. As shown in figure 6, the Adobe Photoshop® raster-based rendering program is used to create a raster file containing coloring information (for example, tone, shadow, background color) and 610 print information. raster file is processed for the 614 inkjet printer. As shown in figure 6, Wasatch SoftRIP Version 5.1.2 software program from Wasatch Computer Technologies, Inc. processes the file to the compatible format of the jet printer driver. of ink.

After the laser graphic mold and inkjet graphics have been processed in suitable formats, the graphic design elements are laser and inkjet marked 104 and printed 106 on the surface of the article to produce a completed sample 620.

Figures 7 to 11 show a system of laser marking and inkjet printing of graphic design on articles such as construction components using a high-speed, high-power laser and inkjet printer. It should be understood that the elements of the system described below are exemplary and are not necessarily intended to limit the scope of the invention. Other systems and devices can be replaced by those described below, and the system and devices described below can be modified as dictated by the nature of the graphic pattern and the article.

Figure 7 is a schematic view of a system for marking a surface of an article according to an embodiment of the invention. As shown in figure 7, a system according to a modality

18/31 of the invention includes a workstation computer 702, a laser controller 704, a laser 706, a laser scanner 710, an inkjet controller 712, and an inkjet printer apparatus 714.

Workstation computer 702 can be configured to receive a graphic design to be applied to the workpiece or article. As shown in figure 7, the workpiece comprises door frame 300, which comprises a printing surface 718. Workstation computer 702 is in operative communication with a laser controller 704 and a printer controller 712. The 704 laser controller communicates with a 706 laser and 710 laser scanner to direct the path of a 708 laser beam. The 712 inkjet printer controller communicates with a 714 inkjet printing device, discussed in more detail below.

Workstation computer 702 can be, for example, a personal computer system. Computer hardware and software for carrying out the modalities of the invention described in this document can be of any type, for example, either general purpose or some specific purpose, such as a workstation. The 702 workstation computer can be a Centrino® or Pentium® class computer, running Windows XP®, Windows Vista®, Windows 7® or Linux®. Alternatively, workstation computer 702 can be a Macintosh® computer.

The computer program loaded on the workstation 702 computer can be written in C, C ++, C #, Java, Brew or any other suitable programming language. The program can be resident on a storage medium, for example, magnetic or optical, of, for example, a computer hard disk, a disk or removable media, such as a memory card or SD media, or other removable media. Programs can 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 to perform the operations described in this document. Computer-aided design (CAD) software can be

19/31 employee.

In the embodiment illustrated in figure 7, laser 706 generates a laser beam 708 which is passed through the laser scanner 710. The laser controller 704 controls the laser scanner 710 to direct the path of the laser beam 708 across the surface of the door frame 300. The laser scanner 710 directs the path of the laser beam 708 using relatively light coated mirrors (discussed below). The laser controller 704 is able to control the movement of the light mirrors of the laser scanner 710 and, simultaneously, adjust the power for the laser 706 to direct the output of the laser beam 708a along a path that forms the first graphic image element. on the door frame 300.

The laser scanner 710 and the inkjet printing device 714 are in close proximity to a work platform, or bed, 716 that supports the door frame 300, which in the illustrated embodiment is a door frame in one state prefabricated. The door frame 300 can alternatively be a door lining or door trim. In figure 7, the laser scanner 710 is upstream of the inkjet printer device 714. In other embodiments, the inkjet printer device can be upstream of the laser scanner 710. In addition, several modalities can comprise multiple lasers 706 and / or multiple inkjet printer devices 714.

The work platform 716 and / or the door frame 300 are moved relative to the directed laser beam 708a and the inkjet print head (not shown in figure 7) of the printing device 714 to create the desired graphic design . As used herein, relative movement may include movement of the directed laser beam 708a and / or the movement of an inkjet print head of the inkjet printer apparatus 714 in the vicinity of the door frame 300 and / or platform working 716, while bed 716 and / or door frame 300 remain stationary. The relative moment can further understand the movement of the work platform 716 and / or the door frame 300, while the laser beam directed 708a and the print head a

20/31 inkjet of the inkjet printing device 714 remain stationary. In addition, the relative movement may include the combined movement of the directed laser 708a, inkjet print head of the inkjet printer apparatus 714, bed 716 and / or door frame 300.

Figure 8 is a schematic view of a laser and laser controller of the system of Figure 7, according to an embodiment of the invention. The system shown in figure 8 comprises the computer workstation 702, which is in communication with the laser controller 704. The laser controller 704 is in communication with the laser 706, an x-axis galvanometer x 802, a geometric axis y 806, and a tank 812.

The 710 laser scanner comprises a computer controlled mirror system. The illustrated mirror system includes an x 804 geometry axis mirror, rotatably mounted on and driven by an x 802 geometry axis galvanometer. The x-axis galvanometer x 802 is adapted to rotate and cause the x-axis mirror x 804 to rotate. The rotation of the x-axis mirror x 804, while the laser beam 708 is incident on the mirror 804 causes the beam of laser 708 incident on mirror 808 to move along the geometric axis x. The 704 laser controller can be configured to control the rotation of the x804 geometry axis mirror by the x80 geometry axis galvanometer, regulating the power supplied to the x80 geometry axis galvanometer.

The 708 laser beam is deflected by the x 804 geometry axis mirror and directed towards a y 808 geometry axis mirror rotatably mounted on the y 806 geometry axis galvanometer. The y 806 geometry axis galvanometer is adapted to rotate and cause rotation of the y axis mirror 808. Rotation of the y axis mirror 808 causes the laser beam 708 to move on the mirror 808 along the y axis. The laser controller 704 can also be configured to control the rotation of the y-axis mirror by the y-axis galvanometer through energy regulation

21/31 supplied to the y-axis galvanometer y 806.

The speed and power of the 708a laser are regulated to reproduce high-resolution graphics with the laser marker. For example, the laser controller 704 can rotate the x80 geometry axis galvanometer and the 806 geometry axis galvanometer at high rates to increase the speed of the directed laser beam 708a across the surface of the door frame 300. The speed of the directed laser beam 708a can determine the appropriate power level for the laser while the graph is laser marked. Certain characteristics of the graphic design, such as the complexity, intricacy and depth of the design, can influence how the graphic design is laser marked on the door frame 300.

The 708 laser beam is deflected by the geometric axis mirror y 808 and directed through a focusing device 810 adapted to focus the 708 laser beam on a 708a directed laser beam. The focusing apparatus 810 may comprise a set of multiple flat field focusing lens elements, which optically maintain the focused point (i.e., the focal point) on a flat surface while the directed laser beam 708a moves through the frame port 300 for laser marking a graphic design element, such as a channel 308. Although not shown, lens 810, mirrors 804, 808 and galvanometers 802, 806 can be housed in a galvanometer block.

The work platform 716 can be a solid substrate or even a fluidized bed. The door frame 300 is placed on the work platform 716. The door frame 300 comprises a visible, laser-marking and ink-printable surface, which in an exemplary embodiment corresponds to the outer surface of a door covering. The work platform 716 can be adjusted vertically to adjust the distance from the lens 810 to the print surface 718. The laser beam 708 is directed by mirrors 804, 808 to cause the laser beam directed 708a to be incident on the surface of the door frame 300.

22/31

The laser beam directed 708a is typically directed along a path generally perpendicular to the laser marking surface 718, but different graphics can be achieved by adjusting the angle between the laser beam directed 708a and the laser marking surface 718, for example, from about 45D to about 135ü. The relative movement between the directed laser beam 708a incident on the laser marking surface 718 of the door frame 300 causes a graph such as the channel 12 to be laser marked on the laser marking surface 718. As mentioned here, the movement relative motion may involve the movement of the directed laser beam 708a (for example, using the mirror system) while the door frame 300 remains stationary, the movement of the door structure 300, while the directed laser beam 708a remains stationary, or a combination of simultaneous movement of the directed laser beam 708a and the door frame 300 in different directions and / or at different speeds.

According to an exemplary implementation, a graphic design is scanned or otherwise introduced into the computer's workstation 702 and converted to the appropriate format, for example, digitized. Information corresponding to the characteristics of the laser-marked graphic image is communicated to the 704 laser controller with instructions for laser marking graphic design elements on their corresponding sections. The laser controller 704 then controls the movement of the galvanometers 802, 806 and the power output of the 706 laser to mark the first graphic element on the work surface 718 of the door frame 300 at the power and speed of the laser. motion suitable for high performance. The power of the laser beam, the size of the laser beam, and the speed of the laser beam can be controlled to avoid any undesirable consequences of over-treatment, such as complete carbonization, burning and / or melting of the door frame 300 The system can also include a 718 tank to inject a gas as an inert gas into the work area. The amount of gas can be controlled by the workstation computer 702, the gas controller

23/31 laser 704, or some other device.

In an exemplary embodiment, a 2,000-watt laser is coupled to an ultra-high speed laser scanner 710 capable of moving the laser beam 708a over the printing surface 718 at more than 30 meters per second. In other modalities, lasers with other power measurements, up to and above 2,500 watts, and laser scanners with different scanning speeds, up to and above 65 meters per second are used. Laser scanning speeds of 30 to 50 meters per second can mark graphic design in time structure measured in seconds per square meter and unit costs measured in cents per square meter. As noted here, speed is the relative speed of the directed laser beam 708a relative to the work surface 718. The relative speed can be controlled by moving the directed laser beam 708a, keeping the work surface 718 in a stationary position, moving the surface of work 718, and keeping the directed laser beam 708a in a stationary position, or at the same time moving the directed laser beam 708a and the working surface 718 in different directions and / or at different rates.

According to an exemplary embodiment, a high-speed, high-power laser is used to form the first graphic design element on the surface of the door frame 300. The 706 laser can be a high-power CO2 laser with an output power 500 W, 1000 W (1 kW), 2000 W (2 kW), 2500 W (2.5 kW), or higher. The power output of the laser referred to here is continuous, as distinguished from the output power when a laser has a temporary energy surge, or when the laser is pulsed. The continuous power can be varied by adjusting the power of the 706 laser. The frequency of the 708 laser beam is typically in the range, for example, 10 to 60 kHz. An exemplary commercial laser, such as a 2.5 kW CO ₂ laser, model number DC025, is available from RofinSinar Technologies, Inc.

In order to provide a 1,000 to 2,500 watt laser system that is driven by a galvanometer at high scan speeds,

24/31 for example, ranging from 30 to 50 meters / second, available in lightweight mirror systems with high temperature coatings are particularly useful. One such commercially available lightweight mirror system is the ScanLab AG 3-axis galvanometer scanner, Model PowerSCAN33 Be, with 33 mm Be mirrors. The high temperature coating is believed to be an alloy of deposited physical vapor. The light beryllium substrate is coated with materials that allow the mirror surface to reflect more than 98% of the CO2 wavelength, 10.6 microns. Lightweight mirror systems allow galvanometers to move the directed laser beam 708a in a repeatable but efficient manner over the printing surface 718. The scanning speed of such a laser system can be an order of magnitude higher than the laser scanning speed achieved with both linear drives and conventional galvanometer mirrors. Using such a lightweight mirror system, laser scanning speeds above 65 meters per second can be achieved in comparison with maximum scanning speeds of 4 to 5 meters per second, with conventional laser engraving technology.

In one example, a system for laser engraving of plastic boards, in a continuous process for mass production, may comprise the operation of a 2500 watt laser at high speeds and directed to a 50.8 cm (20) work surface. inches) to match the process line speed. However, in order to laser mark 0.91 meter by 2.44 meters (3 feet by 8 feet) internal doors for mass production, it may be more efficient to employ multiple lasers or a linear motor to cover the entire surface. of work. Regardless of the layout, laser powers of 500 watts and higher (for example, 500 to 2,500 watts) and laser scan speeds of 10 meters per second and higher (for example, 10 to 50 meters per second) produce satisfactory savings of unit costs of lazing on construction products. Reductions in real unit costs may be reduced by an order of magnitude,

25/31 dollars-per-square-foot to cents-per-square-foot, increasing the laser speed from 3.8 meters per second, to, for example, 50 meters per second.

Systems and methods for surface marking of articles can be made using several other laser systems and scanning devices, having modified layouts and elements alternative to that shown in figure 8. Examples of laser systems are described in the US Patent Application Publications No. 2007/0108170 to Costin et al. and WO / 2008/156620 to Costin et al., whose descriptions are incorporated by reference.

The inkjet printing apparatus 714 is configured for inkjet printing of graphic drawings on a workpiece, such as door frame 300. Door frame 300, which comprises a printing surface 718, is supported on the work platform 716, which can be the same work platform or different work platform used to support the door frame 300 during laser marking. Preferably the work platform 716 is capable of supporting several objects and moving the objects in relation to the inkjet printing device 714 for continuous manufacturing.

Figure 9 is a schematic view of an inkjet printing apparatus of the system of Figure 7, according to an embodiment of the invention. As shown in figure 9, the inkjet printing device 714 consists of coating station 902, drying station 904, printing station 906, finishing station 910, and finishing curing station 912. The workpiece , like the door frame 300, can move on the work platform 716 in a sequential order through the inkjet printing apparatus 714, moving from the coating station 902 to the drying station 904, the printing station 906, the finishing station 910, and ending at the finishing curing station 912.

Coating station 902 can be configured to spray or apply a base coat to the outer surface of the

26/31 door 300. Multiple base coatings can be applied to the outer surface of the door frame 300, such as a first base coat on a larger flat part 302 and inner panels 310 and a second base coat on channels 308. The second base coat po5 to provide a shading suggestion on channels 308. A darker shade on channels 308 can provide a richer appearance. The base coatings (s) may comprise a colored paint, such as a color simulating a wood tone such as mahogany. Coating station 902 may comprise a hand gun or an automatic robotic sprayer10. If a wood fiber pattern is to be inkjet printed or laser marked, the base coating (s) can contribute to the replication of the wood fiber pattern background tone.

After leaving coating station 902, the door frame may enter a drying station 904. Drying station 15 gem 904 can cure or dry one or more layers of base coatings of door frame 300. The station drying unit 904 may include an induction radiation heater for drying the base coat, or some other pigment drying device.

The door frame 300 is then sent to a printing station 906 and the selected image is printed in inkjet on the outside of the door frame 300. The printing station 906 can comprise a UV curing lamp 908. In one embodiment For example, the ink printed on the outer surface of the door frame 300 is UV curable. A commercially available UV-curable ink is UV-curable Sericol ink, however other UV-curable inks can be used. The UV curable ink is then cured by the UV curing lamp 908.

After leaving the printing station 906, the door frame 300 can enter the finishing station 910. The finishing station 910 can apply a finish or protective layer, such as a UV-curable coating. The finish can be, for example, a clear varnish. The finish can be sprayed or applied to the surface

27/31 external structure of door frame 300. Finally, the finish can be dried in a UV 912 finishing curing station.

Figure 10 is a schematic view of a printing station of the printing apparatus of Figure 9 according to an embodiment of the invention. The print station 906 comprises an inkjet printer 1002, which includes at least one inkjet print head 1004. The inkjet print head 1004 is in communication with the inkjet printer controller 712 The inkjet print head 1004 is mounted for movement in a direction perpendicular to the direction of movement of the door frame 300. Arrow 1006 shows the direction of movement of the inkjet print head 1004, and arrow 1008 shows the direction of movement of the work platform 716. The inkjet print head 1004 is preferably movable along direction 1006 across the width of the door frame 300. Printer 1002 can be a flatbed printer, as available through Inca Digital Printers Limited of Cambridge, UK.

Figure 11 is a schematic view of the inkjet printer of Figure 9 according to an embodiment of the invention. As shown in figure 11, the printer 1002 includes a rail 1102 to support the inkjet print head 1004. Rail 1102 provides lateral movement of the inkjet print head 1004 under the control of the jet print controller ink cartridge 712. The inkjet print head 1004 is shown with a UV curing lamp 1104 for drying and curing inkjet ink. Alternatively, a separate curing station, such as the UV curing lamp 908, can be provided. Drops of inkjet ink 1106 are emitted from nozzles 1108 of the inkjet print head 1004.

The nozzle outlets of the inkjet print head 1004 move in a plane P2 that is separated from the plane P of the door frame 300 by a space G. Therefore, the distance traveled by the ink drops 1106 emitted by nozzles 1108 varies depending on whether the 1004 inkjet print head is on the flat part (for example, the larger flat part

28/31 or panels 14) or over one of the 308 channels. If the distance is too great, the inkjet printed images may become cloudy, particularly in the 308 channels.

Nozzles 1108 have a diameter above and below 20 microns. The droplets 1106 will have a diameter approximately equal to the diameter of the nozzles 1108. For example, a Spectra NovaJet 256 inkjet print head can be used, which creates droplets with a diameter of about 40 microns. The relative speed of the inkjet print head 1004 and the angle of the nozzles 1108 with respect to the P2 plane (for example, the nozzles 1108 can be tilted) define the angle of incidence at which a droplet 84 is emitted from the nozzle 1108 with respect to the upper face of the door frame 300.

It is to be understood that the inkjet printer 1002 can include multiple inkjet print heads 1004 arranged in lines or dies, so that each pass can print effectively in more than one set of positions on the printing grid. Nozzles 1108 can emit ink jet drops 1106 of various desired colors in order to create a desired color. Further description and information about the inkjet printing device 714 can be found in U.S. Patent No. 7,001,016, the description of which is incorporated herein by reference. EXAMPLES

To demonstrate the influence of substrate material and graphic pattern on laser power and scan speed, the experiments set out in Table I below were performed on various substrates.

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Table I

Substrate Graphic Image Laser Power (Watts) Scanning speed (m / s) PVC composite Cedar 1750 10 Polyethylene Wood Composite Cedar 2500 10 Polyethylene Wood Composite Board 2000 10 Polyethylene Wood Composite Leopard 1750 10 Compensated Walnut 2500 15 Painted MDF (2 layers of paint) Simple Oak 2500 40 Medium Density Fiber Board (MDF) Rose Petals 2500 15 Medium Density Fiber Board (MDF) Simple Walnut 1500 22 Medium Density Fiber Board (MDF) Cross Fiber Oak 1500 22 Painted Compact Plate (2 layers of paint) Board 1375 15 Painted Compact Plate (1 layer of paint) Simple Oak 2500 28 Compressed Compact Plate Simple Oak 2500 32 PVC Cedar 2500 10 Injected Molded Plastics - Reaction Cedar 2250 10

The effects of the controller speed on the width of the laser power variation for two separate graphic images are shown in Tables II and III below. Table II contains data for 32 laser lines per inch and Table III contains data for 60 laser lines per inch. For example, a graphic image with 32 lines per inch requiring the laser power to vary every two pixels can reach a maximum laser scanning speed of 15 m / s at a speed of

30/31 controller of 10,000 pixels per second (see Table II). In order to double the laser speed to 30 m / s, in this case, the controller must have a processing power of 20,000 pixels per second. As the laser lines per inch increase (comparing Table II with Table 5 III), the speed of the controller becomes more important for keeping the speed of the laser line high.

Table II

Specific Graph at 32 lines / inch Power Variation Width (Pixels) Controller Speed (Pixels / second) Laser Scanning Speed (m / s) 4 10,000 31 4 20,000 62 3 10,000 23 3 20,000 46 2 10,000 15 2 20,000 30 1 10,000 7 1 20,000 14 1 40,000 28 1 50,000 35

Table III

Specific Chart at 60 lines / inch Power Variation Width (Pixels) Controller Speed (Pixels / second) Laser Scanning Speed (m / s) 4 10,000 16 4 20,000 32 3 10,000 12 3 20,000 24 2 10,000 8 2 20,000 16 1 10,000 4 1 20,000 8 1 40,000 16 1 50,000 20

The foregoing detailed description of certain exemplary e31 / 31 modalities of the invention has been provided for the purpose of explaining the principles of the invention and their practical application, thereby allowing others skilled in the art to understand the invention for various modalities and with various modifications while they are suitable. for the private use contemplated. This description is not intended to be exhaustive or to limit the invention to the precise modalities described. Although only a few modalities have been described in detail above, other modalities are possible and the inventors intend for them to be encompassed within this specification and within the scope of the appended claims. The specification describes specific examples to achieve a more general objective that can be achieved in another way. Modifications and equivalents will be evident to those skilled in the art and are encompassed within the spirit and scope of the attached claims and their appropriate equivalents. This description is intended to be exemplary, and the claims are intended to cover any modification or alternative that may be predictable to a person skilled in the art. For example, other types and powers of lasers, in addition to those described above, could be used with this technique.

Only those claims that use the words means to should be interpreted under 35 USC 112, sixth paragraph. In addition, no limitation from the specification should be read in any claim, unless those limitations are expressly included in the claims.

Claims (20)

1. The method of marking the surface of an article, comprising: laser marking of a first graphic design element on the surface of an article; and inkjet printing a second graphic design element in the predetermined orientation with the first graphic design element on the surface of the article. A method according to claim 1, further comprising: receive a graphic design; generate a laser graphic template comprising one or more characteristics of the graphic design to be laser marked on the article; generating a first graphic design element based at least in part on the laser graphic template; generating an inkjet graphic template comprising one or more characteristics of the graphic design to be inkjet printed on the article; and generating a second graphic design element based at least in part on the inkjet graphic template. Method according to one of claims 1 or 2, wherein the first graphic design element and the second design element are combined for visual and tactile printing. Method according to any one of claims 1 to 3, wherein the first graphic design element comprises a channel, an ornamental design, or a simulation of wood. Method according to any one of claims 1 to 4, wherein the second graphic design element comprises a pattern. A method according to any one of claims 1 to 5, where the laser marking precedes inkjet printing. Method according to any one of claims 1 to 6, in which the inkjet printing precedes the laser marking. 2/3 The method according to any one of claims 1 to 7, wherein the laser and printing inkjet marking occur substantially simultaneously. 9. The method of marking the surface of an article, comprising: receive a graphic design; generating a laser graphic template comprising one or more characteristics of the graphic design to be laser marked on the article; generating a first graphic design element based at least 10 in part on the laser graphic template; generating a graphic inkjet template comprising one or more characteristics of the graphic design to be printed by inkjet on the article; and generating a second graphic design element based at least in part on the inkjet graphic template; laser mark the first graphic design element on a part of the article surface; and inkjet printing the second graphic design element in predetermined association with the first graphic design element 20 on the surface part of the article. A method according to claim 9, including the step of transferring the inkjet printer on a plane that is not equidistant from the surface of the article and the laser-marked characteristics. 11. Method according to either of claims 9 or 10, including 25 including the stage of inkjet printing and printing with UV curable ink. 12. Method according to any one of claims 9 to 11, including the step of laser marking a part of the article and inkjet printing a part of the article, at least some part of the jet printing 30 of ink overlapping at least part of the laser marking. 13. Surface marking system of an article, which comprises 3/3 a laser marking device configured to print a first graphic design element on the article surface and an inkjet printing device configured to print a second graphic design element on the article surface, in predetermi5 association with the first graphic design element. A system according to claim 13, wherein the first graphic design element and the second design element are combined for visual and tactile printing. The system according to claim 13 or 14, wherein the first graphic design element comprises a channel, an ornamental design or a wood simulation. The system according to any one of claims 13 to 15, wherein the second graphic design element comprises a pattern. 15 17. Article comprising: a first laser-marked graphic design element on an article surface; and a second inkjet printed graphic design element in predetermined orientation with respect to the first graphic design element on the article surface. An article according to claim 17, wherein the first graphic design element and the second design element are combined for visual and tactile printing. 19. An article according to claim 17 or 18, wherein the The first graphic design element comprises a channel, an ornamental design or a wood simulation. An article according to any one of claims 17 to 19, wherein the second graphic design element comprises a pattern.