Foaming Device Pivoting Mold Plates Wedge Shape
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Solution Overview
Problem
Existing methods for producing wedge-shaped insulating boards are inefficient, leading to costly and time-consuming cutting processes that result in material damage and waste, with the current methods failing to produce high-quality, cost-effective wedge-shaped insulation panels.
Innovation Solution
A foaming device with a pivoting mechanism that allows for the angular adjustment of mold plates within the foaming mold, enabling the direct production of wedge-shaped insulating boards without the need for subsequent cutting, thereby eliminating material waste and surface damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If wedge-shaped insulating boards are produced by cutting a foamed block, then the desired wedge shape is achieved, but material damage and waste occur, and production time increases
Solution Approach 1:
The mold plate is pre-adjusted to the required wedge angle before the foaming process begins. This preliminary positioning of the mold plate at the correct angle allows the insulating board to be formed with the desired wedge shape directly during foaming, eliminating the need for subsequent cutting operations that would cause material waste.
Solution Approach 2:
The angle of the mold plate is changed from a standard position to a specific wedge angle. By adjusting the mold plate's angular parameter, the foaming process directly produces the wedge shape, transforming the manufacturing approach from post-formation cutting to in-process shaping, thereby preventing material loss.
2Shape
If wedge-shaped insulating boards are produced by cutting a foamed block, then the desired wedge shape is achieved, but production time increases
Solution Approach 1:
The mold plate is pre-adjusted to the required wedge angle before the foaming process begins. This preliminary positioning of the mold plate at the correct angle allows the insulating board to be formed with the desired wedge shape directly during foaming, eliminating the need for subsequent cutting operations that would consume additional production time.
Solution Approach 2:
The wedge shape is formed continuously during the foaming process itself, rather than requiring a separate discontinuous cutting step. The mold plate maintains the wedge angle throughout the entire foaming operation, integrating the shaping function into the primary manufacturing process and eliminating time-consuming post-processing.
3Ease of manufacture
If the mold plate is fixed at a standard angle, then the manufacturing process is simple, but wedge-shaped insulating boards cannot be produced
Solution Approach 1:
The mold plate is designed with adjustable angular positioning capability, transitioning from a fixed standard angle to a dynamically adjustable angle. This allows the mold plate to be set to different wedge angles as required, providing versatility for producing various wedge-shaped insulating boards while maintaining a relatively simple adjustment mechanism.
Solution Approach 2:
The mold plate serves multiple functions: it acts as both the standard molding surface for regular insulating boards and the wedge-shaped molding surface for sloped roof panels. By incorporating angular adjustability, a single mold plate can produce different product geometries, eliminating the need for multiple specialized molds and simplifying the overall manufacturing system.
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
The insulation board manufacturing apparatus (01) has a mold plate (06) which forms a cover, where another mold plate (05) forms a base of a building. The base forming mold plate is designed opposite the cover forming mold plate. A pivoting device (11) is equipped with a pivot drive (12.1,12.2) for adjusting the angular arrangement of one mold plate relative to the other mold plate. Independent claims are also included for the following: (1) an insulation board for building insulation, particularly made of expanded polystyrene; and (2) a foaming machine for production of insulation boards.