Pressed Waxy Cleaning Blocks Using Low-Pressure Vibration
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Solution Overview
Problem
Existing methods for producing waxy solid cleaning compositions are energy-intensive, destroy desirable ingredients, require expensive equipment, and are not suitable for forming larger solid blocks, limiting their practical application in institutional and industrial settings.
Innovation Solution
A method involving gentle pressing and optional vibration of flowable waxy particles using a concrete block machine or turntable press to form stable solid cleaning compositions, employing pressures of 6.895 to 6895 kPa (1 to 1000 psi) and vibration frequencies of 3000 to 6000 rpm, without the need for high-pressure tableting, melting, or extrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If conventional tablet press is used to form solid cleaning compositions, then high pressure can be applied to form tablets, but the equipment is expensive and not suitable for making solid blocks
Solution Approach 1:
The patent applies a concrete block machine, originally designed for construction purposes, to the production of solid cleaning compositions. This multi-functional application allows the use of simple, inexpensive equipment for a different purpose, eliminating the need for expensive specialized tablet presses while achieving the required compression for solid block formation
Solution Approach 2:
The invention uses inexpensive, readily available concrete block making equipment instead of expensive, specialized pharmaceutical or cosmetic tablet presses. The simple mechanical press and mold system can be easily constructed or obtained, providing a cost-effective solution for producing solid cleaning compositions in various sizes including large blocks
2Shape
If casting method is used to make waxy solid compositions, then solid blocks can be formed, but energy is consumed for melting and certain ingredients may be destroyed
Solution Approach 1:
The patent incorporates ingredients into the waxy composition in their final solid or semi-solid form before molding, eliminating the need for subsequent melting steps. The composition is prepared and formulated at ambient or moderate temperatures, preserving heat-sensitive ingredients while still enabling solid block formation through mechanical compression and vibration
Solution Approach 2:
The invention replaces the thermal process (melting and casting) with a mechanical process (compression and vibration). Instead of using heat to form solid blocks, the patent uses mechanical force applied through a concrete block machine to compact the waxy composition into the desired solid block shape, thereby avoiding energy-intensive heating and potential ingredient degradation
3Shape
If extrusion method is used to make waxy solid compositions, then solid forms can be produced, but expensive equipment and advanced technical know how are required
Solution Approach 1:
The patent uses a concrete block machine, a simple and universally available piece of equipment from the construction industry, to produce solid cleaning compositions. This eliminates the need for specialized extrusion equipment and advanced technical knowledge, making the production process accessible and cost-effective while still achieving solid block formation
Solution Approach 2:
The invention employs inexpensive, simple equipment (concrete block machine and molds) instead of expensive extrusion systems. The basic mechanical components can be easily constructed or obtained, requiring minimal technical expertise to operate, thereby dramatically reducing both equipment costs and technical barriers to entry
4Manufacturing precision
If high pressure is applied to form solid compositions, then dense solids can be produced, but the process is energy-intensive and not suitable for large blocks
Solution Approach 1:
The patent incorporates vibration as a key step in the solid block formation process. The concrete block machine applies vibrations to the waxy composition during compression, which helps achieve dense packing and proper shape formation at lower pressures compared to static compression methods. The vibration facilitates particle rearrangement and eliminates air pockets, achieving manufacturing precision with reduced energy input
Solution Approach 2:
The patent employs cyclic or periodic compression and vibration cycles during the solid block formation process. Rather than applying continuous high pressure, the system uses repeated cycles of compression, vibration, and release, which progressively densifies the material while maintaining lower peak pressures and reducing overall energy consumption. This periodic action is particularly effective for forming large blocks
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
Produces stable solid cleaning compositions in various sizes, including large blocks, without energy-intensive processes, preserving desirable ingredients and enabling efficient production of larger products.
Implementation Method 1
gently pressing and optionally vibrating flowable waxy particles determines the shape and density of the solid
Implementation Method 2
The method can employ a concrete block machine and/or a turntable press for pressing and optionally vibrating
Data Source
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AI summary
The present invention relates to a method of making a solid cleaning composition. The method can include pressing and/or vibrating flowable waxy particles of a waxy cleaning composition. For a waxy cleaning composition, pressing and/or vibrating flowable waxy particles determines the shape and density of the solid but is not required for forming a solid. The method can employ a concrete block machine for pressing and/or vibrating. The present invention also relates to a solid cleaning composition made by the method and to solid cleaning compositions including particles bound together by a binding agent.