Slab Mold Base Frame Integration for Durability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional molds for manufacturing slabs face durability issues due to the use of adhesion layers that can corrode and wear down, leading to separation of the base and frame parts, resulting in inefficient and less durable products.
Innovation Solution
A mold design integrating a base part and a frame part without an adhesion layer, using cross-linked polymers in the rubber layers with varying curing agent compositions, and incorporating quartz for enhanced wear resistance, along with a manufacturing method involving sequential lamination and heating processes to ensure strong coupling between the base and frame parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesion layers are used to join base and frame parts, then the mold can be manufactured with separate components, but the adhesion layers corrode and wear down leading to separation and reduced durability
Solution Approach 1:
The base part and frame part are integrated into a single monolithic structure through direct molding, eliminating the adhesion layer interface that causes corrosion and separation. The rubber composition is molded to form both parts as one unified component, ensuring structural integrity and durability while maintaining ease of manufacture.
Solution Approach 2:
The adhesion layer is completely removed from the mold structure. By extracting this problematic intermediate layer, the invention eliminates the source of corrosion and separation issues, allowing the base and frame parts to be directly formed as an integrated structure without vulnerable joining interfaces.
2Device complexity
If adhesion layers are used to connect base and frame parts, then the mold can be assembled from separate parts, but the adhesion layers wear down causing separation and manufacturing inefficiency
Solution Approach 1:
The base part and frame part are combined into a single integrated molded structure, eliminating the need for separate assembly steps and adhesion layer application. This reduces device complexity by removing unnecessary components and interfaces while improving productivity by streamlining the manufacturing process into a single molding operation.
Solution Approach 2:
The adhesion layer and associated assembly processes are extracted and removed from the manufacturing system. This eliminates the wear and separation problems caused by adhesion layers while simplifying the overall device structure and reducing manufacturing steps, thereby improving both complexity and efficiency metrics.
3Ease of manufacture
If uniform curing agent composition is used in rubber layers, then the manufacturing process is simpler, but the base and frame parts do not achieve strong coupling
Solution Approach 1:
The curing agent composition is optimized locally for different regions of the rubber layers. The first and second rubber layers have different curing agent contents tailored to their specific functional requirements, enabling strong coupling between the base and frame parts while maintaining ease of manufacture through a controlled lamination process.
Solution Approach 2:
The rubber layers are constructed as composite structures with varying curing agent compositions. By creating a laminated composite of multiple rubber layers with different curing characteristics, the invention achieves both strong inter-layer coupling and ease of manufacture through the systematic arrangement of materials with complementary properties.
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 solution provides a mold with excellent durability and manufacturing efficiency by eliminating adhesion layer-related issues, ensuring uniformity and strength, and simplifying the manufacturing process.
Implementation Method 1
each of the base part and the frame part may include a polymer, and the polymer of the base part and the polymer of the frame part may be cross-linked with each other
Implementation Method 2
performing a second pressing and heating process of pressing and heating the first rubber composition, the second rubber composition, the first fabric layer, the third rubber composition, and the second fabric layer by using the press
Data Source
AI summary
The present disclosure herein relates to a mold for manufacturing a slab. More particularly, the mold includes a first fabric layer, a first rubber layer disposed on the first fabric layer, a second fabric layer disposed on the first rubber layer, and a second rubber layer disposed on the second fabric layer. Here, the second rubber layer includes a base part and a frame part extending from an edge of the base part. Also, the base part and the frame part are integrated with each other.