Stone Block Stabilization via Cast Containment Jacket

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Solution Overview

Problem

The existing methods for producing stone slabs from extracted blocks face challenges such as macro defects, cracks, and structural discontinuities, leading to instability and safety risks during handling and cutting, due to imprecise movement and lack of planarity, resulting in costly and hazardous manual stabilization processes.

Innovation Solution

A method involving the creation of a containment jacket using a hardening material with a cementitious or polymeric component, which is cast around the block to form a stable, planar base, allowing for precise handling and cutting operations by providing structural stability and preventing vibrations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a crane is used to move large stone blocks, then the block can be lifted and translated, but the movement precision is insufficient for mechanical processing requirements

Engineering Contradiction:

Improveblock movement capabilityVSAvoidpositioning precision

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

A movable platform is introduced as an intermediary device between the crane and the stone block. The platform receives the block from the crane and provides precise positioning capabilities, separating the functions of heavy lifting (crane) and precise positioning (platform with adjustment mechanisms).

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The movement and positioning system is segmented into distinct functional components: the crane handles lifting and rough transport, while the movable platform with its adjustment mechanisms handles precise positioning. This division allows each component to be optimized for its specific function.

Inventive Principle:

Principle #1Segmentation

2Measurement precision

If the block is moved and repositioned multiple times, then better positioning can be achieved, but the block becomes increasingly unstable and prone to breakage

Engineering Contradiction:

Improvepositioning accuracyVSAvoidblock stability

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The movable platform is designed with built-in stabilization features and adjustment mechanisms that are prepared in advance. The platform can immediately provide stable, precise positioning when the block is placed on it, eliminating the need for multiple repositioning operations that would compromise block stability.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If manual stabilization operations are performed multiple times, then block stability is improved, but the process becomes expensive and hazardous for operators

Engineering Contradiction:

Improveblock stabilityVSAvoidstabilization process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The movable platform is designed to automatically stabilize the block through its built-in adjustment mechanisms and positioning systems. The platform self-adjusts to provide the correct positioning and stability without requiring multiple manual stabilization operations, thereby reducing process complexity and hazard levels.

Inventive Principle:

Principle #25Self-service

4Productivity

If the block is cut into slabs without precise stabilization, then the cutting operation can proceed, but the slabs may open fan-shaped and the cutting parallelism cannot be guaranteed

Engineering Contradiction:

Improvecutting operation continuityVSAvoidcutting parallelism

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The movable platform provides precise positioning and stabilization of the block before the cutting operation begins. This preliminary action ensures that the block is firmly held in the correct position, guaranteeing that the cutting blades can proceed continuously and produce parallel, fan-shaped-free slabs.

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

This method enhances the integrity and safety of the stone block by enabling precise handling and cutting, maintaining structural stability even during sequential sectioning, and reducing the risk of accidents by stabilizing the block and allowing for parallelism between cutting planes and external surfaces.

Implementation Method 1

a hardening material with a cementitious or polymeric component, which is cast around the block to form a stable, planar base

Methodology Applied

Scientific EffectHardening:

Data Source

PatentEP3768481B1Method of producing slabs of stone material including a step of stabilizing a block of stone material

Publication Date: 2022.04.27 SFERA SRL

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AI summary

The present invention relates to a method for stabilizing a block M of stone material comprising the use of a hardening material as a filling material for filling cavities and / or geometrical disconnections of a base surface of the block of stone material.