Reverse Demoulding Mould for Building Coatings
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Solution Overview
Problem
Existing moulds for building coating products, such as artificial stones, are prone to deformation and wear due to their flexible nature, leading to high labour costs for manual unmoulding and frequent replacement, which increases production costs and results in aesthetic issues like visible sealing furrows.
Innovation Solution
A mould with reverse demoulding, consisting of a rigid base plate, a deformable die, and a rigid moulding grid, allowing for precise and automated production without deformation, using a combination of materials like steel and polyurethane rubber, with a specific reverse demoulding angle for easy extraction and reassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If flexible polyurethane rubber moulds are used to easily detach finished products, then ease of operation is improved, but reliability deteriorates due to deformation and wear over time
Solution Approach 1:
The mould is divided into two separate halves: a rigid base plate with die and a rigid moulding grid. This segmentation allows each part to maintain structural integrity while collectively providing easy unmoulding through the grid's design, eliminating the wear and deformation issues of flexible single-piece moulds
Solution Approach 2:
Instead of making the entire mould flexible for easy unmoulding, the invention inverts the approach by using rigid materials with a specific geometric configuration (moulding grid with inverted cone shapes) that enables easy product extraction without requiring material flexibility, thus maintaining reliability
2Ease of operation
If flexible moulds are used to accommodate undercuts, then ease of operation is improved, but manufacturing precision deteriorates due to permanent deformation
Solution Approach 1:
The invention inverts the traditional approach by not relying on material flexibility to handle undercuts. Instead, rigid moulding grid elements with inverted cone shapes and specific geometric configurations enable easy extraction of products with undercuts while maintaining precise dimensional accuracy through the rigidity of the materials
Solution Approach 2:
The solution moves from relying on material property flexibility to a geometric configuration solution. The inverted cone shapes and specific angular configurations in the rigid moulding grid create dimensional features that facilitate unmoulding without requiring the mould material itself to be flexible, thus preserving manufacturing precision
3Ease of operation
If manual unmoulding operations are used, then ease of operation is maintained, but productivity deteriorates due to high labour costs and time consumption
Solution Approach 1:
The mould design enables self-service unmoulding where the rigid moulding grid with inverted cone shapes automatically facilitates product extraction through its geometric configuration, reducing or eliminating the need for manual intervention and associated labour costs while maintaining operational simplicity
Solution Approach 2:
The invention transitions from manual operation to a system where the mould's geometric design (inverted cones, specific angles) performs the unmoulding function automatically, inverting the role from human labour to engineered geometric features, thus dramatically improving productivity
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
The solution provides a durable, cost-effective, and precise method for producing coating products, reducing assembly difficulties and aesthetic issues, while enabling automated production processes, thus lowering overall production costs and enhancing product quality.
Implementation Method 1
a die (16), made of a resilient and deformable material, for incorporating the base plate (12) inside it
Data Source
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AI summary
A mould (10) for building coating products (100) obtained from composite liquid mixtures is described. The mould (10) comprises a base plate (12), manufactured from a rigid indeformable material and provided with a plurality of through holes (14); a die (16), manufactured from a resilient and deformable material and configured for incorporating the base plate (12) therein, on the upper surface of such a die (16) there being obtained a plurality of shapes (20) of the front surface in negative of each coating product (100) to be manufactured; and a moulding grid (18) open at the upper part, manufactured from a rigid indeformable material and configured to be pressure applied above the die (16), the moulding grid (18) being provided with a plurality of side walls (24) which define the perimeter edges of each coating product (100) to be manufactured. Between the side walls (24) of the moulding grid (18) separate bowls (26) are formed for containing a single coating product (100). Each side wall (24) is inclined according to an acute angle with respect to a vertical plane, so as to confer to each side wall (24) a sharp- pointed and tapered shape from top towards bottom with respect to the entire mould (10) for facilitating the extraction of the finished coating products (100) from such a mould (10).