One-In-Two-Out PVC Foamed Slat Mold with Symmetric Flow Channels
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Solution Overview
Problem
Conventional forming molds for PVC foamed slats have low production efficiency due to their one-in-one-out design, leading to high raw material costs, heavy weight, and poor thermal insulation.
Innovation Solution
A forming mold with a one-in-two-out design featuring symmetrically arranged main flow passages with specific included angles and dimensions, allowing for efficient passage of PVC foam material and integration of a skin material to form a stable, lightweight product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a one-in-one-out forming mold design is used for making PVC foamed slats, then the mold structure is simple, but the production efficiency is low
Solution Approach 1:
The forming mold is segmented into multiple independent flow passages (at least two) that share a common inlet, allowing simultaneous formation of multiple slats. Each flow passage is an independent channel with its own outlet, enabling parallel production while maintaining structural organization through the shared inlet design.
Solution Approach 2:
Multiple flow passages are merged by sharing a common inlet structure, combining the functions of multiple separate molds into one integrated system. This allows multiple slats to be produced simultaneously from a single injection point, improving productivity without proportionally increasing the number of separate mold components.
2Weight of moving object
If aluminum or iron flakes are used for curtain slats, then the structural strength is sufficient, but the weight of the finished product is heavy
Solution Approach 1:
The material parameter is changed from dense metals (aluminum or iron) to foamed PVC material. This parameter change reduces the density and weight of the slat while maintaining sufficient structural strength through the cellular foam structure, achieving the desired weight reduction without completely sacrificing mechanical properties.
Solution Approach 2:
The slat is formed as a composite structure using PVC foam material that combines the benefits of plastic (light weight, corrosion resistance) with foamed structure (thermal insulation, reduced density). This composite approach replaces traditional metal materials while achieving multiple performance improvements simultaneously.
3Temperature
If aluminum or iron flakes are used for curtain slats, then the structural strength is sufficient, but the thermal insulation effect is poor due to heat absorption
Solution Approach 1:
The thermal parameter of the material is changed by transitioning from metal (high thermal conductivity) to foamed PVC (low thermal conductivity). The foamed structure introduces air pockets that act as thermal insulators, significantly improving thermal insulation performance while the PVC base material maintains sufficient structural strength for the application.
Solution Approach 2:
The foamed PVC material acts as a composite structure where the PVC matrix provides structural integrity and the foam cells provide thermal insulation. This composite structure simultaneously achieves both requirements: sufficient strength from the PVC framework and good thermal insulation from the trapped air in the foam cells.
Data Source
AI summary
A forming mold for making polyvinyl chloride foamed wood-like slats includes an inlet, an outlet, and two main flow passages symmetrically arranged with respect to a central axis. The main flow passages each have an inlet section respectively connected to the inlet and an outlet section respectively connected to the outlet. The extension direction of the inlet section of each main flow passage respectively defines with the central axis an included angle therebetween. The sum of the angles of the two included angles ranges from 44.2 to 48.8 degrees. The width of the main flow passages gradually increases from the inlet toward the outlets. The height of the main flow passages gradually reduces from the inlet toward the outlets. In this way, the forming mold of the present invention can effectively improve production efficiency and can increase the stability of the product manufacturing process.