Vacuum-Adhered PVA Sheet for Agglomerate Slab Mould Protection
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Solution Overview
Problem
Existing methods for producing slabs of agglomerate face challenges such as uneven application and drying of protective agents, which can lead to pores, undulations, and increased costs due to the need for ovens, and require complex nozzle cleaning and mechanical removal of protective sheets, resulting in low-quality slabs.
Innovation Solution
A plant and method utilizing a station with air suction means to secure an elastic sheet of plastic protective material over the mould impression, ensuring uniform adhesion and easy removal of the slab, with a PVA-based adhesive layer applied in small quantities to prevent wrinkles and solubilization, allowing for efficient vacuum vibrocompression and subsequent easy separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fluid separating/protective agent is sprayed onto the rubberized sheets, then the sheets are protected from resin and solvents and separation is enabled, but the application becomes complex requiring spraying equipment, drying ovens, and regular nozzle cleaning
Solution Approach 1:
The patent applies a disposable solid plastic sheet (preferably PVA-based) as a protective separator between the mould and the slab. This single-use sheet eliminates the need for complex spraying equipment, drying ovens, and nozzle maintenance. The sheet is discarded after one use, simplifying the entire protective agent application system while maintaining reliable protection and separation functionality.
2Reliability
If a large quantity of fluid separating agent is applied to obtain a compact layer, then protection is sufficient, but drying time increases and uniformity becomes difficult to maintain
Solution Approach 1:
The disposable solid plastic sheet provides sufficient protection in a single application without requiring large quantities or extended drying times. The sheet's solid form inherently maintains uniformity and compactness, eliminating the time-consuming drying process required for fluid agents while ensuring reliable protection against resin and solvents.
3Ease of operation
If the protective agent is applied at high temperature to ensure fluidity, then application is easier, but excessive water evaporation occurs losing fluid characteristics
Solution Approach 1:
The solid plastic sheet is applied at ambient temperature, eliminating the need for high-temperature heating that causes excessive water evaporation. The sheet's solid state ensures it maintains its structural integrity and uniformity during application without requiring temperature control, thereby preserving manufacturing precision while remaining easy to operate.
4Area of stationary object
If spraying is used to apply the protective agent, then coverage can be achieved, but nozzle cleaning becomes complex due to the sticky nature of the solution
Solution Approach 1:
The solid plastic sheet is applied as a complete sheet rather than sprayed, eliminating nozzles entirely from the process. This disposable sheet approach provides full mould surface coverage without requiring any spraying equipment, thereby completely avoiding the complex and time-consuming nozzle cleaning operation while maintaining ease of repair.
5Reliability
If PVA solution is sprayed and dried in ovens, then a protective film is formed, but the process requires substantial electric energy and increases plant dimensions
Solution Approach 1:
The solid plastic sheet provides protective film functionality without requiring energy-intensive drying ovens. The sheet is applied in its solid state and maintains its protective properties immediately, eliminating the need for substantial electric energy input while avoiding the need to increase plant dimensions to accommodate large drying equipment.
6Ease of operation
If mechanical removal of protective sheets is required, then separation from mould is achieved, but slab quality decreases due to potential damage
Solution Approach 1:
The disposable PVA-based plastic sheet is designed to separate easily from the hardened slab through dissolution in water during subsequent processing, rather than requiring mechanical removal. This eliminates the risk of slab damage associated with mechanical separation while maintaining ease of operation, thereby preserving slab quality.
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 approach ensures high-quality slabs with reduced material waste, lower energy costs, and simplified processing by preventing sheet entrapment and enabling easy removal, while maintaining adequate adhesion to the mould for smooth operation.
Implementation Method 1
air suction means (53) connected to suction ducts (54) present in the mould (11) so as to allow suction of the air between the sheet and this surface of the impression and bring the sheet against this surface of the impression by means of a vacuum
Implementation Method 2
a PVA-based adhesive layer applied in small quantities to prevent wrinkles and solubilization
Data Source
AI summary
A plant for the production of slabs from a mixture of agglomerate comprises a station (50) with a mixture distribution unit (52) which pours the mixture onto the inner surface of a slab forming mould (11) present in the station. The mould (11) is provided with a sheet (15) of plastic protective material arranged above the inner surface of the mould and which forms the surface for contact with the mixture which is introduced into the mould by the distribution unit (52). The station comprises air suction means which are coupled/connected to suction ducts (54) which are present in the mould and which emerge with their front end inside the mould in a zone of the mould situated between the inner surface of the mould and the sheet (15), so as to allow the suction of air between the sheet and this inner surface and bring the sheet (15) against this surface by means of a vacuum. A method for the production of slabs is also described.