Artificial Marble Stripe Pattern via Slurry Vortex
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Solution Overview
Problem
Existing methods for manufacturing artificial marble fail to replicate the natural stripe patterns of natural stone, resulting in artificial products that lack the desired aesthetic similarity.
Innovation Solution
A method involving a molding box with a moving steel belt and a roller that compresses and discharges colored slurry mixtures, creating a vortex to form a stripe pattern similar to natural stone, using a combination of different colored slurries with varying viscosities and base resins like acrylic, unsaturated polyester, or epoxy, and controlled supply and belt rates to achieve a natural look.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods using various sizes of pigments or chips are used, then artificial marble can be manufactured with controlled composition, but the pattern is very different from that of natural marble
Solution Approach 1:
The patent changes the physical and chemical parameters of the slurry mixture, including viscosity control through specific resin selections (acrylic, unsaturated polyester, or epoxy) and viscosity modifiers, to enable the slurry to form natural-looking stripe patterns when compressed and discharged. This parameter adjustment allows the slurry to self-organize into stripe patterns similar to natural stone during the manufacturing process.
Solution Approach 2:
The patent replaces complex mechanical mixing and layering systems with a simpler compression and discharge mechanism using a roller. By controlling the compression force and discharge rate, the system naturally forms stripe patterns without requiring complex mechanical arrangements for pattern creation, thus improving pattern similarity while maintaining ease of manufacture.
2Manufacturing precision
If multiple colored slurries are mixed to create patterns, then color variety is achieved, but uniformity and control of stripe pattern formation become difficult
Solution Approach 1:
The patent applies different colored slurries with specific local properties (different viscosities and base resins) to create distinct regions that naturally separate into stripe patterns during compression. Each slurry component has optimized local characteristics that facilitate controlled pattern formation, achieving uniform stripes through localized material properties rather than complex global control mechanisms.
Solution Approach 2:
The patent uses composite slurry formulations combining multiple colored slurries with different base resins (acrylic, unsaturated polyester, epoxy) and viscosity modifiers. These composite materials interact during compression to naturally form uniform stripe patterns, achieving pattern control through material composition rather than complex device mechanisms.
3Productivity
If slurry is compressed using a roller spaced a predetermined distance from the belt, then discharge control is achieved, but the complexity of positioning and spacing control increases
Solution Approach 1:
The patent optimizes the spacing parameter between the roller and belt to a predetermined distance that naturally controls the discharge rate and stripe pattern formation. By carefully selecting this geometric parameter, the system achieves controlled productivity without requiring complex active positioning or feedback systems, as the fixed spacing itself regulates the process.
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 method effectively produces artificial marble with a stripe pattern that closely mimics the appearance of natural stone, achieving a natural texture and gradation between stripes.
Implementation Method 1
compressing and discharging a part of the slurry mixture provided into the molding box to be contained at the predetermined height at the lower side of the molding box in the first direction using a roller spaced a predetermined distance apart from the belt in a vertical direction
Data Source
AI summary
The present invention relates to a method and device for manufacturing artificial marble. According to the present invention, artificial marble having a stripe pattern similar to that of natural stone, such as striato, may be provided.