Modular Mould System for Sandwich Construction Elements
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Solution Overview
Problem
Existing moulds for manufacturing floor and wall parts with sandwich structures are limited in flexibility, as each mould element can only produce one specific type of dimension, requiring custom-made elements for different sizes, which increases costs and reduces efficiency.
Innovation Solution
A modular mould system comprising base mould elements and auxiliary mould elements that can be combined to achieve various dimensions and offsets, allowing for the production of floor and wall parts with different sizes without the need for numerous custom elements, and includes features like movable upper plates and magnetic couplings for efficient assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom-made mould elements are used for each specific dimension, then manufacturing precision is improved, but device complexity and costs increase
Solution Approach 1:
The mould is divided into base mould elements that form a standardized grid system. These modular units can be selectively combined to create different dimensional configurations, eliminating the need for custom-made moulds for each dimension while maintaining manufacturing precision through the standardized modular interface.
Solution Approach 2:
Base mould elements are designed with universal functionality to serve multiple purposes. Each standardized mould element can be positioned and combined in various configurations to produce different floor and wall part dimensions, making a single type of mould element applicable to multiple production scenarios.
2Adaptability or versatility
If multiple custom mould elements are manufactured for different dimensions, then adaptability is improved, but loss of substance increases due to unused portions
Solution Approach 1:
By segmenting the mould into reusable base elements that form a grid system, the invention enables adaptive dimensional configuration without creating dedicated moulds for each size. This segmentation allows the same modular components to be reconfigured for different production runs, eliminating material waste associated with custom mould fabrication.
Solution Approach 2:
The modular base mould elements are designed to be removed, recovered, and reused across different production cycles. Instead of discarding or storing specialized mould elements for each dimension, the standardized components are recovered after each use and repositioned for the next production requirement, minimizing material waste.
3Manufacturing precision
If fixed mould configurations are used for each dimension type, then manufacturing precision is maintained, but productivity decreases due to reconfiguration time
Solution Approach 1:
The mould system transitions from static, fixed configurations to a dynamic modular assembly. Base mould elements can be quickly repositioned and recombined according to production requirements, allowing the mould to adapt its configuration dynamically without sacrificing dimensional accuracy. This dynamic capability eliminates reconfiguration downtime between different product types.
Solution Approach 2:
The standardized base mould elements are pre-designed with universal connection interfaces and positioning features. This preliminary design work enables rapid assembly and reconfiguration during production changes, as the modular components are already prepared for versatile combination without requiring time-consuming customization or recalibration.
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 1E~1F
AI summary
The invention relates to a mould (2), a system and method for manufacturing a floor part or a wall part with a sandwich structure. The mould (2) comprises: - a number of lower base mould elements (4), wherein the number of lower base mould elements (4) can be placed mutually adjacently on a base (6) for the floor part or the wall part for the purpose of forming a periphery for a first concrete layer (14); - a first layer of auxiliary mould elements (10), wherein the number of auxiliary mould elements (10) can be placed mutually adjacently on the number of lower base mould elements (4) for the purpose of forming a periphery for an insulating layer (16) and/or second concrete layer (18) arranged above the first concrete layer (14).