Curved Surface Mold with Rope Base for Construction Panels
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Solution Overview
Problem
Conventional construction panel molds are limited to producing flat panels and cannot efficiently manufacture construction panels with curved surfaces, leading to increased costs and reduced reusability due to damage during panel removal.
Innovation Solution
A mold with a curved surface formed by a continuous connection of a rope, comprising first and second side panels, a woven curved base, and a sheet member made of latex or silicone, allowing for the repeated production of construction panels with various curved surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If rigid wood and metal panels are processed to create curved molds, then construction panels with curved surfaces can be manufactured, but the molds often get damaged during panel removal and cannot be reused repeatedly
Solution Approach 1:
The patent applies a flexible sheet member made of latex or silicone that can elastically deform during panel removal. This flexibility allows the sheet to return to its original curved shape after each use, preventing damage and enabling repeated reuse. The thin film structure conforms to the curved base while maintaining enough elasticity to avoid permanent deformation or tearing during the demolding process.
2Adaptability or versatility
If a new mold is made for each specific curve, then construction panels with various curved surfaces can be manufactured, but manufacturing costs increase due to inability to reuse molds
Solution Approach 1:
The mold is segmented into a reusable rigid frame structure (side panels and curved base) and a replaceable flexible sheet member. The curved base is constructed from a rope framework that can be reconfigured to create different curved surfaces. This segmentation allows the expensive rigid components to be reused while only the consumable sheet member needs replacement, significantly reducing overall manufacturing costs for various curved panel designs.
Solution Approach 2:
The rope framework of the curved base is designed to be dynamically reconfigurable, allowing different curve configurations to be created by rearranging the rope structure. This dynamic adaptability enables a single mold system to produce multiple different curved surfaces without requiring separate rigid molds for each design, thereby reducing manufacturing costs while maintaining versatility.
3Ease of manufacture
If conventional flat molds are used, then manufacturing process is simple, but construction panels with curved surfaces cannot be manufactured
Solution Approach 1:
The flexible sheet member acts as an intermediary between the simple rigid frame structure and the desired curved surface. The sheet is draped over the rope framework to transfer the curved geometry to the construction panel material. This intermediary approach maintains manufacturing simplicity by using basic rigid components while achieving complex curved surfaces through the flexible mediator layer.
Data Source
AI summary
The present inventive concept relates to a mold and a construction panel manufacturing method using same, in which, in order to manufacture a construction panel, a surface on which a raw material is applied is formed into a curved surface by continuously connecting a rope. The mold comprises: first and second side plates facing each other; a curved base forming a predetermined curved surface between the first and second side plates by being interweaved to the first and second side plates; and a sheet member disposed along the curved base so as to form the curved surface, and enabling a construction panel raw material to be applied thereon. Thus, construction panels having variously-shaped curved surfaces may be manufactured by repeatedly using the first and second side plates while differing the interweaving of a rope so as to correspond to a curved surface of a construction panel to be manufactured. Accordingly, the present inventive concept has the effect of having excellent manufacturing efficiency for construction panels having curved surfaces.