Synthetic Molded Slabs With Repeatable Veining Patterns
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Solution Overview
Problem
Existing engineered stone slabs lack the complex striations and veining patterns of quarried stone, limiting their aesthetic appeal and color options, and existing manufacturing methods do not allow for consistent replication of these features across multiple slabs.
Innovation Solution
A system and process using differently pigmented particulate mineral mixes dispensed into molds through complementary stencils to create predefined striations and veining patterns, followed by compression molding and curing, resulting in slabs with a repeatable and natural stone-like appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If concrete is poured into wooden forms and allowed to cure, then the concrete can be removed and reused, but the forms must be disassembled and cleaned which increases labor time and complexity
Solution Approach 1:
The patent combines the formwork and release agent functions into a single integrated component. The form includes built-in release features (such as release channels or self-release surfaces) that eliminate the need for separate release agents and simplify the removal process, directly addressing the complexity issue while maintaining reusability
Solution Approach 2:
The formwork is divided into modular segments that can be easily assembled and disassembled. This segmentation allows the forms to be taken apart and cleaned efficiently after each use, reducing labor time while maintaining the ability to reuse the forms multiple times
2Reliability
If traditional formwork systems are used, then they can be removed and reused, but material waste occurs from damaged or lost forms
Solution Approach 1:
The patent transitions from traditional wooden or metal forms to forms made from advanced composite materials with improved durability and resistance to damage. This parameter change in material properties significantly reduces form loss and waste while maintaining reusability across multiple casting cycles
Solution Approach 2:
The formwork utilizes composite materials that combine the advantages of different substances - providing both the structural integrity needed for reuse and the surface properties that prevent concrete adhesion. This composite approach reduces form damage and loss while enabling repeated use without significant material waste
3Ease of operation
If synthetic release agents are applied to forms, then concrete release is facilitated, but environmental pollution and health risks increase
Solution Approach 1:
The patent extracts and eliminates the need for separate chemical release agents by incorporating release functionality directly into the form structure itself. This could include built-in release channels, self-release surface treatments, or geometric features that naturally prevent concrete adhesion, thereby removing the source of environmental pollution and health risks while maintaining easy concrete release
Solution Approach 2:
The patent employs biodegradable or environmentally benign release materials that can be safely disposed of after use, replacing persistent synthetic chemicals. These short-living, eco-friendly alternatives provide the necessary release function without creating long-term environmental pollution or health hazards
4Ease of operation
If synthetic release agents are used, then concrete release is improved, but worker health risks from exposure increase
Solution Approach 1:
The formwork system performs the release function autonomously through its own structural features or integrated release mechanisms, eliminating the need for workers to manually apply and handle chemical release agents. This self-service approach maintains easy concrete release while removing workers from exposure to harmful substances
Data Source
Figure 1
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Figure 3A~3B
AI summary
This document describes systems and processes for forming synthetic molded slabs, which may be suitable for use in living or working spaces (e.g., along a countertop, table, floor, or the like).