Vacuum Vibrocompression for Non-Flat Agglomerated Stone
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Solution Overview
Problem
Current methods for manufacturing non-flat agglomerated stone products, such as sinks and washbowls, are limited by the inability to produce three-dimensional objects with complex surfaces using vacuum vibrocompression, as existing techniques either result in aesthetically poor joints or require high resin content, which affects color differentiation and grain size limitations.
Innovation Solution
A method involving the use of an open-top mold with a demolding agent, subjected to vacuum, pressure, and vibration to shape and compact a mixture of aggregates and organic binder, allowing for the production of non-flat products with varied colors and grain sizes, and subsequent calibration and polishing for desired finishes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If pieces are adhered together to manufacture non-flat products, then three-dimensional shapes can be achieved, but aesthetically poor joints and reduced durability result
Solution Approach 1:
The invention divides the manufacturing process into two independent stages: first producing flat agglomerated panels with optimal material composition, then shaping them into three-dimensional forms through surface modeling techniques. This segmentation eliminates joints by keeping the product as a single monolithic piece throughout shaping, while maintaining aesthetic integrity through the flexibility of surface manipulation.
Solution Approach 2:
The flat panel is prepared in advance with optimized material properties and surface characteristics before the shaping operation. The preliminary flat panel manufacturing allows for perfect homogenization and material distribution, which then serves as a stable base for subsequent three-dimensional shaping without compromising structural integrity or creating weak joints.
2Adaptability or versatility
If high resin content is used to enable complex shaping, then three-dimensional products can be manufactured, but color differentiation and grain size variety are reduced
Solution Approach 1:
The invention separates the material mixing function from the shaping function. The flat panel stage uses optimal resin content (6-13%) for excellent color differentiation and grain size variety, while the subsequent surface modeling stage provides the shaping capability. This segmentation allows each stage to operate with optimal parameters independent of the other.
Solution Approach 2:
The flat agglomerated panel serves as an intermediary between material preparation and final three-dimensional shaping. It acts as a stable, aesthetically optimized base that can be transformed into complex shapes through surface modeling techniques, thereby decoupling the requirements for color differentiation from those for shaping capability.
3Shape
If traditional pressing methods are used, then flat panels can be produced, but non-flat products with complex surfaces cannot be manufactured
Solution Approach 1:
The invention transitions from static pressing molds to dynamic surface modeling techniques. While the initial panel is produced through traditional pressing, subsequent three-dimensional shaping is achieved through dynamic manipulation of the panel surface using modeling tools and techniques, allowing for continuous adaptation to complex geometric requirements.
Solution Approach 2:
The invention adds a temporal dimension to the manufacturing process by separating panel production from shape formation. The flat panel is first created in two dimensions with optimal material properties, then transformed into three-dimensional forms through subsequent surface modeling operations, thereby achieving shape variety without compromising material 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
Enables the production of aesthetically appealing, non-flat agglomerated stone products suitable for both indoor and outdoor use, with improved joint durability and color differentiation, while reducing mold recovery time and production costs.
Implementation Method 1
The mold is subsequently subjected to vacuum for the purpose of extracting the occluded air in the mass
Implementation Method 2
pressure and vibration are then applied to the mass to continue extracting the air and compacting the mass
Data Source
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AI summary
The invention relates to a method for manufacturing non-flat agglomerated stone products, such as sinks, washbowls, etc., by means of vacuum vibrocompression. A mold into which a molding mass is discharged is used in the method. The method allows obtaining products with two or more differentiated colors.