Adjustable Mould Labyrinth for Plastic Tube Bending
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Solution Overview
Problem
The existing moulds for bending plastic or rubber tubes in furnaces or with steam are complex to produce, wear out quickly, and lack precision in repeated production, making them difficult to maintain and replace accurately.
Innovation Solution
The mould features connecting flanges for adjustable connection between parts, allowing for precise turning and angling, and utilizes 3D scanning and printing to create reproducible, identical labyrinth shapes, enabling efficient production and replacement of individual parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional moulds are used for bending plastic or rubber tubes, then the moulds can be produced, but they are complex to produce, wear out quickly, and lack precision in repeated production
Solution Approach 1:
The mould is divided into multiple detachable parts that can be assembled together. Each part can be produced separately with high precision using 3D printing, and then assembled to form the complete mould. This segmentation allows for easier production of individual components while maintaining overall precision through standardized connection elements.
Solution Approach 2:
A 3D scan of the master mould is created, which serves as a digital copy. This digital model can be repeatedly printed using 3D printing technology, ensuring that each mould produced from the scan has identical dimensions and geometry. This eliminates the complexity of repeatedly crafting moulds by hand while maintaining precise reproduction of the original design.
2Reliability
If traditional moulds are used, then bending can be performed, but the moulds wear out quickly and are difficult to maintain and replace accurately
Solution Approach 1:
The mould is constructed from multiple detachable parts with standardized connection flanges. When wear occurs, only the worn parts need to be replaced rather than the entire mould. The modular design allows for easy disassembly and replacement of individual components, significantly improving maintenance ease while maintaining overall system reliability.
Solution Approach 2:
The 3D scanned master mould serves as a permanent digital reference that can be used to reproduce worn or damaged moulds. This digital copy ensures that replacement moulds are identical to the original, maintaining consistent performance and eliminating the need for manual recrafting, thereby improving both reliability and ease of replacement.
3Manufacturing precision
If connecting flanges with adjustment capability are used, then precise turning and angling are enabled, but the device complexity increases
Solution Approach 1:
The connecting flanges are designed with universal features that allow for multiple functions: they provide structural connection between mould parts, enable adjustment of turning angles, and allow for precise positioning. By incorporating adjustment capabilities directly into the connection elements, the design achieves multi-functionality without requiring separate adjustment mechanisms, thereby limiting the increase in overall device complexity.
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 solution simplifies the production of moulds, ensures reproducible accuracy, and allows for easy adjustment and replacement of parts, reducing production time and maintaining consistent quality across multiple iterations.
Implementation Method 1
the adjusted labyrinth is scanned by a 3D scanner
Implementation Method 2
a digital 3D model of the individual parts of the labyrinth is created for a 3D printer, whereupon at least a part of the labyrinth is created on a 3D printer
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a mould for furnace/steam bending of plastic or rubber tubes, which comprises a shaping labyrinth (3). The shaping labyrinth (3) comprises at least two adjacent parts (I, II), each of which is provided at the end intended to connect to the adjoining part with a connecting flange (6) for joining the adjacent parts (I, II) of the labyrinth (3). The invention also relates to a method of producing a mould for furnace/steam bending of plastic or rubber tubes, in which is formed a shaping labyrinth (3), whose shape is subsequently adjusted according to the control master jig of the tube to be shaped. Afteradjustement of the shape of the labyrinth (3), the adjusted labyrinth (3) is scanned by a 3D scanner and subsequently a digital 3D model of the individual parts (I, II) of the labyrinth (3) is created for the 3D printer, whereupon at least one part (I, II) of the labyrinth (3) is printed on the 3D printer and the individual parts (I, II) of the labyrinth (3) are joined, the surface is blurred and, optionally, the adjacent parts (I, II) of the labyrinth (3) are additionally joined also undetachably, apart from being joined detachably.