Artificial Stone Slab Vein Formation for Natural Edges and Binding
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Solution Overview
Problem
Existing methods for manufacturing artificial stone slabs with veins result in a non-natural appearance and increased risk of infiltration or breaking due to sharp edges between materials, lacking a method to achieve a more natural-looking and improved binding between materials.
Innovation Solution
A method involving the deposition of a pattern of veins using a second hardenable fluid mixture on a first layer, followed by vacuum and vibration, where the second material's fluidity and density differences cause it to rise or sink relative to the first and third materials, creating a blurred and uneven vein edge, enhancing the natural appearance and binding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a precise pattern of veins is created using inserts or manual piping, then the vein pattern is well-defined with sharp edges, but the appearance becomes non-natural and the risk of infiltration or breaking increases
Solution Approach 1:
The patent changes the physical parameters of the vein material by using a more fluid mixture with different viscosity and density characteristics. This allows the vein material to naturally diffuse and blend with the surrounding matrix material during pouring, creating organic, blurred edges rather than sharp defined lines, thereby improving both appearance and structural integrity
Solution Approach 2:
The vein pattern is created through the self-organizing behavior of the fluid mixtures during the pouring process. The density and viscosity differences between the vein material and matrix material cause automatic separation and pattern formation without requiring external tools or manual intervention, allowing the materials to self-define their boundaries naturally
2Shape
If different colored mixtures are stacked in alternate layers, then thick veins are formed, but the precise path or geometry of veins cannot be defined
Solution Approach 1:
The patent segments the mixture into multiple fluid layers with different compositions, colors, and densities before pouring. Each layer can be independently formulated with specific properties, allowing precise control over the final vein pattern geometry while maintaining thickness variability through the layered structure
3Manufacturing precision
If sharp edges are used between vein material and matrix material, then the vein pattern is clearly defined, but the binding between materials is weakened and breakage risk increases
Solution Approach 1:
The patent modifies the rheological parameters of the materials by adjusting viscosity, density, and fluidity to enable gradual transitions between vein and matrix regions. This creates a gradient structure at the interfaces rather than abrupt boundaries, improving material binding while maintaining visual definition through controlled optical properties
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 produces an artificial stone slab with a more natural-looking pattern of veins and improved material binding, reducing the risk of infiltration and breakage by blurring the vein edges and increasing resistance.
Implementation Method 1
applying vacuum and vibration, and also optionally compression, to the hardenable fluid mixtures
Implementation Method 2
applying vacuum and vibration, and also optionally compression, to the hardenable fluid mixtures
Implementation Method 3
the second material's fluidity and density differences cause it to rise or sink relative to the first and third materials
Implementation Method 4
curing said hardenable fluid mixtures producing the hardening thereof
Data Source
AI summary
A method of manufacturing an artificial stone slab comprising pouring a first layer (10) of a first material; depositing a pattern of veins (30) of a second material on the first layer (10) and/or within a pattern of grooves (40) defined therein; depositing a second layer (20) of a third material covering the first layer (10) and the pattern of veins (30), applying vacuum and vibration to the materials and curing said materials obtaining the artificial stone slab; wherein the third material is less fluid and/or denser than the second material, the vibration producing the raising of the second material through the second layer (20); or the first material is more fluid and/or less dense than the second material, the vibration producing the sinking of the second material through the first layer (10).