Molded Solid Surfaces With Magnetic Ferrous Particle Patterning

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Solution Overview

Problem

Natural and engineered stone surfaces are expensive and require specialized equipment, limiting their availability and applicability, while lacking cost-effective alternatives with desirable aesthetics.

Innovation Solution

Manufacturing molded solid surfaces with ferrous particles using localized magnetic fields to create predetermined patterns or docking locations, utilizing resinous materials like acrylic, polyester, or epoxy, and incorporating ferrous particles such as iron dust, which can be recovered from waste streams, to form aesthetic designs or secure accessories.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If natural and engineered stone surfaces are used, then desirable aesthetics are achieved, but cost and equipment requirements increase significantly

Engineering Contradiction:

ImproveaestheticsVSAvoidcost and equipment requirements

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The patent replaces expensive natural and engineered stone surfaces with a cost-effective molded solid surface composition that achieves similar aesthetic effects through ferrous particle patterns, making high-quality surfaces accessible without specialized equipment

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention creates a composite material system combining resinous material with ferrous particles to replicate the visual characteristics of stone surfaces while enabling versatile molding and customization at lower cost

Inventive Principle:

Principle #40Composite materials

2Ease of operation

If ferrous particles are distributed uniformly in the molded solid surface, then material simplicity is maintained, but pattern creation capability is lost

Engineering Contradiction:

Improvematerial simplicityVSAvoidpattern creation capability

Core Design Contradiction:

Ease of operationVSAdaptability or versatility

Solution Approach 1:

The patent applies localized magnetic fields to specific regions during molding to concentrate ferrous particles in predetermined patterns, allowing different areas of the solid surface to have different particle concentrations and visual characteristics while maintaining a uniform base composition

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention replaces mechanical mixing and distribution methods with magnetic field application to control ferrous particle positioning, enabling precise pattern creation without complex mechanical systems or manual intervention

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If ferrous particles are concentrated in specific areas using magnetic fields, then pattern precision is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvepattern precisionVSAvoidmanufacturing complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent uses magnetic fields as an intermediary mechanism to control ferrous particle distribution, where the magnetic field acts as a mediator between the molding process and the final pattern formation, simplifying the direct control requirements

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention incorporates ferrous particles into the resinous material before molding and applies magnetic fields during the molding process to pre-position particles in desired patterns before the material sets, ensuring precision without post-processing complexity

Inventive Principle:

Principle #10Preliminary action

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

Provides cost-effective alternatives to natural and engineered stone surfaces with desirable aesthetics and functional docking capabilities, offering affordable and versatile solid surfaces for kitchen and bathroom applications.

Implementation Method 1

a magnetic field is applied to move the ferrous particles and create a predetermined pattern or docking location

Methodology Applied

Scientific EffectMagnetic field: Magnetic Field

Implementation Method 2

Ferrous particles such as iron dust, which can be recovered from waste streams

Methodology Applied

Scientific EffectFerromagnetism: Ferromagnetism

Data Source

PatentUS12472665B2Molded solid surfaces including ferrous material

Publication Date: 2025.11.18 KOHLER CO(US)

AI summary

A method of manufacturing a molded solid surface includes mixing ferrous particles into a resinous material, injecting the resinous material including the ferrous particles into a mold, the mold including an upper mold half and a lower mold half, creating a predetermined pattern in the resinous material by applying a force to the ferrous particles in the resinous material toward a surface of the upper mold half or the lower mold half using one or more magnets, and curing the resinous material in the mold into the molded solid surface.