Curing Containers with Airflow Apertures for Stone Packaging
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Solution Overview
Problem
The existing methods for manufacturing and shipping manufactured stone products are costly due to labor-intensive loading and unloading processes and can result in unsightly staining from condensation when stones are not fully cured before shipping.
Innovation Solution
Packaging partially cured manufactured stones with wicking material in curing containers that provide airflow apertures for proper drying and curing, allowing for direct shipping in the same containers, reducing the need for additional handling and preventing condensation staining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If stones are packaged for shipping before being fully cured, then shipping time is reduced, but condensation appears on the surface causing staining
Solution Approach 1:
The patent applies preliminary action by providing airflow apertures in the packaging container before shipping. This allows continued curing and drying of the stones during transit, preventing condensation staining without delaying shipping. The airflow paths are pre-established in the container design to facilitate moisture evaporation during the shipping process.
2Reliability
If stones are removed from molds and stacked into ovens for further curing, then proper curing is achieved, but labor and handling costs increase
Solution Approach 1:
The patent merges the packaging function with the curing function by incorporating airflow apertures directly into the shipping container. This eliminates the need for separate curing ovens and multiple handling operations. The container serves dual purposes: protecting stones during shipping and enabling continued curing through its airflow design, thereby reducing labor and handling costs.
Solution Approach 2:
The packaging container is designed with multi-functionality, serving both as a protective shipping vessel and as a curing device. The airflow apertures enable the container to perform the curing function that previously required separate oven equipment, reducing the number of processes and handling steps needed.
3Reliability
If multiple handling operations are performed for curing and packaging, then proper curing is ensured, but productivity decreases
Solution Approach 1:
The patent combines multiple operations into a single integrated process. The airflow container allows stones to be packaged and cured simultaneously during shipping, eliminating separate curing and packaging steps. This integration maintains curing effectiveness while significantly improving shipping efficiency and productivity.
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
This approach reduces labor and handling costs, ensures proper curing and drying, and minimizes defective products by allowing stones to continue curing during shipping, enhancing customer satisfaction.
Implementation Method 1
The wicking material separates at least the outside surfaces of the manufactured stones, allowing for airflow between the surfaces for proper drying of the stones
Implementation Method 2
curing containers having airflow apertures therein... allowing for airflow between the surfaces for proper drying of the stones
Implementation Method 3
airflow apertures... allowing for airflow between the surfaces
Data Source
AI summary
A method of packaging and curing manufactured stone can include packaging a plurality of partially cured de-molded manufactured stones in a curing container having airflow apertures therein. The loaded container is then loaded into a drying oven for further curing for a suitable period. After curing in the oven, the curing container is removed and may be shipped to a customer without unpacking and repacking the manufactured stones.