Adjustable Casting Mould for Directional Insulation Block Cell Shaping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing insulation blocks, such as EPS plates, result in uniform round cell structures, limiting the ability to optimize properties like thermal conductivity, compression strength, and dimensional stability across different directions.
Innovation Solution
A method involving a casting mould with adjustable walls, where pre-expanded polymer beads are steamed and the mould's volume is altered during the steaming and cooling phases to shape cells non-uniformly, allowing for desired property optimization by changing cell shape from round to elongated or oval.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pre-expanded polymer beads are expanded evenly in every direction using a standard-sized mould, then the cell structure becomes round and uniform, but the insulation block properties cannot be optimized differently in different directions
Solution Approach 1:
The patent applies the dynamics principle by making the mould dimensions adjustable during the expansion process. The mould walls can be moved to change the inner volume and shape of the mould cavity, allowing the cell structure to be formed with different shapes (round, elongated, flattened) depending on the direction of expansion constraints. This dynamic adjustment enables directional optimization of insulation properties while maintaining ease of operation.
2Ease of manufacture
If the mould size is fixed during manufacturing, then the manufacturing process is simple, but the cell shape cannot be controlled or formed as desired
Solution Approach 1:
The mould is designed with movable walls that can be adjusted during the expansion process. This dynamic capability allows the mould to transition from a simple fixed structure to a controllable shaping tool, enabling precise cell shape control (round, elongated, flattened) while maintaining relatively simple manufacturing of the mould itself.
Solution Approach 2:
The patent changes the physical parameters of the mould (inner volume, wall positions, cavity shape) during the expansion process. By adjusting these parameters at different stages of bead expansion, the cell shape can be precisely controlled to match desired insulation properties while keeping the manufacturing process straightforward.
3Manufacturing precision
If the inner volume of the casting mould is adjusted during steaming and cooling phases, then cell shape can be controlled to optimize insulation properties, but the manufacturing process becomes more complex
Solution Approach 1:
The mould incorporates movable walls that can be adjusted during steaming and cooling phases. This dynamic adjustment capability enables precise cell shape formation (elongated, flattened, or compressed cells) to optimize insulation properties in specific directions, while the overall device structure remains relatively simple and manageable.
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 tailored insulation properties by altering cell shape, enhancing thermal insulation and compression strength in specific directions without compromising air- and waterproofness, with improved thermal conductivity and dimensional stability.
Implementation Method 1
steaming the pre-expanded polymer beads in the casting mould
Implementation Method 2
the pre-expanded beads expand evenly in every direction
Data Source
AI summary
A method for manufacturing an insulation block, preferably an insulation plate, in which method the casting mold is adjusted to a desired size by moving at least one wall of the casting mold, the pre-expanded polystyrene, polypropylene or polyethylene beads are led to the casting mold, the pre-expanded polymer beads are steamed in the casting mold, and the formed finished insulation block is removed from the mold. In a method according to the invention at least one wall of the casting mold is moved during the steaming and/or during the cooling phase after the steaming.