Movable Mould Wall for Foamed Plastic Production
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Solution Overview
Problem
Existing methods for producing large, plate-like foamed plastic products, such as insulation panels, are inefficient and result in residual waste due to the need for large molds and long conversion times when producing products with different dimensions.
Innovation Solution
A compact device with a box-shaped first mould body and a movable second mould body allows for efficient production of foamed plastic products with adjustable thickness and angle, using steam cavities to maintain temperature and prevent condensation, and enabling quick conversion between different product forms through adjustable mould cavity dimensions and rebates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large block-like mould is used to produce plate-like foamed plastic products, then the product dimensions can be achieved, but residual waste occurs and conversion time is long
Solution Approach 1:
The invention divides the mould into two separate mould bodies (first mould body with box-shaped first mould wall, and second mould body with second mould wall) that can move relative to each other. This segmentation allows the mould cavity to be precisely adjusted to match the exact dimensions of the desired plate-like product, eliminating the need for oversized block moulds and thereby reducing residual waste material.
Solution Approach 2:
The second mould body is made movable to and fro inside the box form of the first mould body, allowing dynamic adjustment of the mould cavity dimensions. This enables precise control over the final product dimensions and thickness, ensuring that the mould cavity exactly matches the required product size rather than producing oversized blocks that require subsequent cutting and generate waste.
2Manufacturing precision
If a large block-like mould is used to produce plate-like foamed plastic products, then the product dimensions can be achieved, but conversion time is long
Solution Approach 1:
The movable second mould body allows rapid adjustment of the mould cavity dimensions by moving along the box-shaped first mould wall. This dynamic capability enables quick conversion between different product sizes and thicknesses without requiring complete mould replacement or extensive reconfiguration, thereby significantly reducing conversion time between different product series.
Solution Approach 2:
The mould device is designed with universal applicability to produce plate-like foamed plastic products of various dimensions and thicknesses using the same mould structure. The movable second mould body can be positioned at different locations within the box form to create mould cavities of different sizes, making the mould multi-functional and eliminating the need for multiple dedicated moulds for different product specifications.
3Volume of stationary object
If steam cavity volume is dependent on matrix cavity size, then large moulds require large steam cavities, but steam efficiency decreases
Solution Approach 1:
The steam cavity is segmented and positioned independently from the mould cavity. The first steam cavity is surrounded by the sealing body except for the first mould wall and second mould wall, allowing the steam cavity volume to be optimized separately from the mould cavity size. This enables efficient steam utilization even when producing large plate-like products, as the steam cavity does not need to scale proportionally with the mould cavity.
Solution Approach 2:
The sealing body acts as an intermediary structure that separates and isolates the steam cavity from the mould cavity. This allows the steam to be efficiently contained and directed into the mould cavity through controlled pathways (first and second mould walls), improving steam efficiency by preventing excessive steam consumption that would occur in a directly proportional steam-mould cavity configuration.
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 the rapid and economical production of foamed plastic products with varying thickness and angles, reducing waste and allowing for complex product designs with short conversion times between different series.
Implementation Method 1
the first steam cavity which, except for the above-mentioned first mould wall and second mould wall, is surrounded by the sealing body
Implementation Method 2
To prevent or at least limit the risk of steam condensing on the first mould wall, it may be advantageous if the device is provided with heating means for heating the first mould wall
Implementation Method 3
Such heating means may comprise a second steam cavity on the outside of the first mould wall, to which steam can be supplied by means of the second supply means
Implementation Method 4
The first mould wall may here furthermore be configured to allow the passage of steam from the second steam cavity to the mould cavity and/or to the first steam cavity
Data Source
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AI summary
The invention creates a device (1; 101) for production of an at least substantially plate-like foamed moulded plastic product (75; 79; 203). The device comprises a frame (2), a mould, first supply means (71) for supplying plastic material to be foamed to the mould cavity (15) of the mould, and second supply means for supplying steam to the mould cavity (15) filled with the plastic material. A first mould body (8; 108) of the mould comprises a box shaped first mould wall (11; 111), a second mould wall (12; 112) on the inside of the box form of the first mould wall (11; 111). The second mould wall (12; 112) adjoins the first mould wall (11;111). Via the second mould wall (12; 112), steam may be supplied to the mould cavity (15). The device (1; 101) furthermore comprises a sealing body (16) on the inside of the first mould wall (11; 111) on the side of the second mould wall (12; 112) facing away from the mould cavity (15). The sealing body (16) adjoins the first mould wall (11; 111), and first sealing means (18, 19) for sealing the seam between the first mould wall (11; 111) and the sealing body (16). A first steam cavity (20) is formed between the first mould wall (11; 111), the second mould wall (12;112) and the sealing body (16). Second supply means are configured for supplying steam from the first steam cavity via the second mould wall (12; 112) to the mould cavity (15). The device (1; 101) comprises furthermore second movement means for jointly moving the second mould wall (12; 112) and the sealing body (16) relative to the first mould wall (11; 111). The invention furthermore creates a number of methods.