Self-Solidifying Cleaning Blocks Using Low-Pressure Pressing
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Solution Overview
Problem
Existing methods for producing solid cleaning compositions, such as those used in institutional and industrial operations, are energy-intensive and require expensive equipment, and conventional tablet presses are unsuitable for making larger solid blocks.
Innovation Solution
A method involving gentle pressing and/or vibrating a flowable solid cleaning composition using a concrete block machine or turntable press to determine shape and density, employing a binding agent to form stable solids without high pressure or melting, allowing for the production of larger solid blocks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high pressure is applied using a tablet press to form solid cleaning compositions, then the solid blocks can be formed with high density and stability, but the equipment cost increases and the method is unsuitable for making larger solid blocks
Solution Approach 1:
The patent changes the pressure parameter from high pressure (tablet press) to low pressure (concrete block machine), and changes the binding mechanism from mechanical compression to chemical bonding through a binding agent system. This allows formation of large solid blocks without requiring expensive high-pressure equipment while maintaining structural stability through the binding agent.
Solution Approach 2:
The patent introduces a binding agent as an intermediary substance that facilitates solid block formation. The binding agent (comprising a hydrate-forming material and a sequestrant) acts as a mediator between the cleaning composition particles, enabling them to bind together into stable solid blocks under low pressure conditions, replacing the need for high-pressure mechanical compression.
2Ease of manufacture
If melting is used to form liquid composition for casting solid blocks, then the composition can be easily formed into desired shapes, but energy consumption increases and certain desirable ingredients may be destroyed
Solution Approach 1:
The patent replaces the thermal processing system (melting and casting) with a mechanical mixing and low-pressure forming system. Instead of heating the composition to a liquid state for formability, the invention uses a binding agent system that allows the composition to be mixed in solid/semi-solid state and formed into solid blocks under low pressure, eliminating the energy-intensive melting step while preserving heat-sensitive ingredients.
Solution Approach 2:
The patent performs preliminary mixing of the binding agent components (hydrate-forming material and sequestrant) with the cleaning composition before the solidification step. This preliminary action ensures the binding agent is uniformly distributed and ready to facilitate solid block formation under low pressure, eliminating the need for subsequent melting or high-energy processing steps.
3Productivity
If extrusion is used to produce solid cleaning compositions, then continuous production is achieved, but expensive equipment and advanced technical know how are required
Solution Approach 1:
The patent employs a concrete block machine that is a versatile, commonly available piece of construction equipment to perform the solid block formation function. This multi-functional approach allows the same type of equipment to be used for various solid block production needs without requiring specialized, expensive extrusion equipment and advanced technical expertise, while still enabling continuous or batch production.
4Manufacturing precision
If conventional tablet press is used to form solid cleaning compositions, then high pressure ensures dense and stable tablets, but the method is not suitable for making larger solid blocks
Solution Approach 1:
The patent changes the pressure parameter from high pressure (suitable for small tablets) to low pressure combined with a chemical binding mechanism. This parameter change enables the formation of large solid blocks that cannot be produced by conventional tablet presses, while the binding agent system maintains the density and stability characteristics associated with high-pressure formation.
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 method produces stable solid cleaning compositions efficiently and cost-effectively, avoiding the need for high-pressure equipment and energy-intensive processes, enabling the creation of larger solid blocks suitable for industrial use.
Implementation Method 1
solid cleaning compositions including particles bound together by a binding agent
Implementation Method 2
pressing and/or vibrating a flowable solid of a self-solidifying cleaning composition
Implementation Method 3
pressing and/or vibrating a flowable solid determines the shape and density of the solid
Data Source
AI summary
The present invention relates to a method of making a solid cleaning composition. The method can include pressing and/or vibrating a flowable solid of a self-solidifying cleaning composition. For a self-solidifying cleaning composition, pressing and/or vibrating a flowable solid 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.