Screening Mask and Pattern Mold for Artificial Marble Vein Clarity
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Solution Overview
Problem
Current artificial marble production methods struggle to accurately replicate the clear boundary and wide stripe patterns of natural stones, resulting in a discrepancy between the artificial and natural stone designs.
Innovation Solution
The use of a screening mask and pattern mold to create an artificial marble with a vein pattern, where 50% or more of the vein pattern has a width of 5 mm to 50 mm, and in cross-section, the vein pattern's thickness is 10% or greater of the total thickness, with a clear boundary between the pattern and base regions, achieved through a manufacturing method involving molding, compression, and curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods (spraying pigment or knife removal) are used to create patterns, then the production process is simple, but the pattern boundary is unclear and the stripe width is insufficient
Solution Approach 1:
The mold is segmented into multiple components: a base mold for the overall structure, and separate pattern molds with convex portions that define the vein patterns. The screening mask is also segmented with multiple openings corresponding to different pattern regions. This segmentation allows each component to perform its specific function independently, achieving clear pattern boundaries without requiring the entire system to be overly complex.
Solution Approach 2:
A screening mask is introduced as an intermediary component between the pattern mold and the base composition. The mask with its specific opening pattern mediates the transfer of the vein pattern design from the mold to the artificial marble, enabling precise pattern formation while keeping the mold structure relatively simple.
2Manufacturing precision
If conventional spraying or knife methods are used, then the equipment is simple, but the vein pattern width and thickness are insufficient to mimic natural stone
Solution Approach 1:
The vein pattern geometry is predetermined and built into the convex portions of the pattern mold before the manufacturing process begins. The convex portions are designed with specific dimensions (width 5-50 mm, thickness 10% or more of total thickness) to pre-establish the desired vein pattern characteristics. This preliminary design of the mold geometry eliminates the need for complex post-processing or multiple adjustment steps during manufacturing.
Solution Approach 2:
The invention specifies precise parameter ranges for the vein pattern: width of 5-50 mm and thickness of 10% or more of the total artificial marble thickness. By changing and controlling these geometric parameters through the mold design, the artificial marble achieves natural stone-like vein dimensions that were not attainable with conventional spraying or knife methods.
3Manufacturing precision
If simple spraying or knife removal is used, then the production cost is low, but the aesthetic appearance does not match natural stone
Solution Approach 1:
The molding system is divided into functional segments: base mold, pattern mold with convex portions, and screening mask with openings. Each segment contributes specifically to achieving clear pattern boundaries, allowing the system to produce high-aesthetic results without requiring every component to be excessively complex.
Solution Approach 2:
The convex portions of the pattern mold and the opening patterns in the screening mask are designed to copy the vein patterns found in natural stones. By replicating the geometric characteristics of natural stone veins through these mold components, the artificial marble achieves an aesthetic appearance that closely matches natural stone without requiring the entire manufacturing system to be overly complex.
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 artificial marble with a clear and sharp boundary between the pattern and base regions, effectively mimicking the appearance of natural stones with a wide vein pattern, enhancing aesthetic appeal.
Implementation Method 1
pressing the pattern mold to compress the base composition
Implementation Method 2
putting a pattern forming composition into the grooves
Implementation Method 3
curing the artificial marble flat plate
Data Source
AI summary
The present invention relates to an artificial marble and a manufacturing method of an artificial marble. In addition, the present invention relates to a screening mask and a pattern mold for manufacturing the artificial marble.