Tombstone Manufacturing Using Elastic Protective Sheet
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Solution Overview
Problem
The high cost and environmental impact of traditional marble tombstones, along with the need for specialized labor and susceptibility to atmospheric agents, are significant challenges in creating affordable and durable memorial markers.
Innovation Solution
A process using a mould with a flexible and elastic protective sheet and thermoplastic polymer to create tombstones with decorative elements, where the sheet is positioned inside the mould, and the polymer is injected to form the tombstone shape, ensuring cost reduction, environmental sustainability, and protection from the elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If marble is used to realise tombstones, then aesthetic appearance and durability are improved, but manufacturing cost and environmental impact worsen
Solution Approach 1:
The patent applies the copying principle by creating a tombstone that replicates the aesthetic appearance of traditional marble tombstones through a different material system. The transparent or translucent polymer matrix with embedded particles or layers reproduces the visual characteristics of marble without requiring actual marble extraction and processing, thereby reducing manufacturing costs while maintaining the desired appearance.
Solution Approach 2:
The patent employs composite materials by combining a transparent or translucent polymer matrix with embedded particles, layers, or inclusions that simulate marble veining and texture. This composite structure achieves the aesthetic and durability properties of marble while using more cost-effective and environmentally friendly materials, resolving the contradiction between material quality and manufacturing cost.
2Reliability
If marble is used to realise tombstones, then aesthetic appearance is improved, but environmental impact worsens
Solution Approach 1:
The patent applies the copying principle by reproducing the aesthetic appearance of marble tombstones through a synthetic material system that does not require extraction from natural quarries. The transparent polymer with embedded decorative elements mimics the visual characteristics of marble while eliminating the environmental harm associated with marble quarrying and processing.
Solution Approach 2:
The patent uses composite materials consisting of a transparent or translucent polymer matrix combined with embedded particles, layers, or inclusions that create marble-like veining and texture. This composite approach achieves the desired aesthetic appearance without depleting natural marble reserves or causing environmental degradation from quarrying operations.
3Manufacturing precision
If traditional processes are used to create decorations and incisions, then aesthetic quality is improved, but manufacturing cost and complexity worsen
Solution Approach 1:
The patent applies the preliminary action principle by incorporating all decorative elements, incisions, and text directly into the mould cavity before the casting process. The mould itself contains the negative impressions of all desired surface features, allowing them to be formed automatically during polymer injection without requiring subsequent manual carving or decoration by specialised operators, thereby reducing both cost and complexity.
Solution Approach 2:
The patent uses the copying principle by transferring the decorative design directly from the mould cavity to the tombstone surface during the casting process. The mould acts as a template that replicates the desired aesthetic features throughout the polymer material, achieving high manufacturing precision through a single automated operation rather than multiple manual steps.
4Device complexity
If tombstones are made without protection, then manufacturing simplicity is improved, but susceptibility to atmospheric agents worsens
Solution Approach 1:
The patent applies the parameter changes principle by selecting a polymer material with specific properties - transparency or translucency combined with inherent resistance to atmospheric agents such as rain, UV radiation, and temperature variations. By changing the material parameter from traditional opaque stone to a weather-resistant transparent polymer, the tombstone maintains manufacturing simplicity while gaining protection against environmental degradation.
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 results in tombstones that are more affordable, environmentally friendly, and protected from atmospheric agents, utilizing recyclable materials and enabling rapid production with decorative elements, while reducing the demand on marble quarries.
Implementation Method 1
injection of a thermoplastic polymer (H) in a molten state into the profiled design (3)
Implementation Method 2
with the cooling and consequent solidification of the thermoplastic polymer
Implementation Method 3
a flexible and elastic protective sheet (7) made of a synthetic resin
Data Source
Figure 1
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AI summary
A process for realising tombstones, comprising following steps: predisposing a die (1) comprising a base (2), in which a profiled design (3) is afforded, a perimeter extension (3A) of which identifies the perimeter extension of a tombstone (L), and delimits an operating surface (6) conformed in a complementary way to the conformation of the front face (10) of the predetermined tombstone (L); positioning a protective sheet (7) of synthetic resin in said profiled design (3) to cover at least the operating surface (6); injecting a thermoplastic polymer in the molten state into the profiled design (3) with a consequent pressure exerted by the weight of the molten polymer on the protective sheet (7) so that the protective sheet (7) deforms elastically to marry the profile of the operating surface (6), the cooling and consequent solidification of the thermoplastic polymer injected into the profiled design leading to a stable joining of the protective sheet (7) to the adjacent surface of the solidified body (40) of thermoplastic polymer injected to define the front face of the predetermined tombstone; extracting, from the profiled design, the whole solidified body (40) - protective sheet (7) assembly which identifies the predetermined tombstone.