Sectorized Moulding Apparatus for Curved-Object Compaction
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Solution Overview
Problem
Existing moulding apparatuses face challenges in producing high-quality objects with complex geometries and uniform compaction, particularly when dealing with materials derived from natural fibers or synthetic polymers, due to difficulties in shaping and inserting doses with non-matching dimensions, leading to defects and inefficient volume reduction.
Innovation Solution
A moulding apparatus with a forming region defined by sectors that can move controllably between enlarged and final configurations, using a punch for transverse compression, and multiple pushing devices to uniformly compress the material, allowing for precise shaping of objects with curved lateral walls and uniform compaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a large initial volume of material is used to accommodate doses with dimensions greater than the finished object, then the dose can be properly inserted into the mould, but the forming region volume cannot be efficiently reduced
Solution Approach 1:
The mould incorporates movable sectors that can dynamically change the forming region volume during the moulding process. The sectors move from an initial position defining a large volume to a final position defining a reduced volume, enabling both easy dose insertion and efficient volume reduction without compromising either requirement
2Ease of manufacture
If simple shaped doses are used for easy production, then the manufacturing process is simplified, but the doses cannot be properly shaped into complex geometries
Solution Approach 1:
The mould is segmented into multiple independent sectors, each with forming surfaces that can be individually positioned and shaped. This segmentation allows the mould to accommodate simple doses while creating complex geometric shapes through the coordinated movement and configuration of the sector forming surfaces
3Manufacturing precision
If high compaction force is applied to reduce material volume, then the material density increases, but the material structure may be damaged
Solution Approach 1:
The movable sectors apply compaction force dynamically as they move from the initial to final position, distributing the compression progressively throughout the material volume. This dynamic approach achieves uniform compaction and high density while maintaining material structure integrity through controlled, progressive deformation
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 production of high-quality objects with uniform physical and mechanical properties, free of defects, by effectively reducing the forming region's volume and accommodating materials with varying initial dimensions, thus achieving versatile and reliable moulding outcomes.
Implementation Method 1
at least a first pushing device for applying, on a first sector of said plurality, a first force directed towards the central zone in a first direction, at least a second pushing device for applying, on a second sector of said plurality, a second force directed towards the central zone in a second direction
Implementation Method 2
the second sector is in contact with the first sector for transmitting the second force to the first sector
Implementation Method 3
a punch arranged for penetrating into the forming region in order to compress the mouldable material
Data Source
Figure 1~2
Figure 3~6
Figure 7
AI summary
A moulding apparatus for forming an object (20) with a mouldable material, the moulding apparatus having a forming region (4) delimited by a lateral surface (5) extending around a central zone (6). The moulding apparatus comprises: a plurality of sectors (8; 80; 108; 208) defining the lateral surface (5), each sector (8; 80; 108; 208) having a body (9) delimited by a forming surface (11; 311), at least a first pushing device for applying, on a first sector (8a) of said plurality, a first force (F1) directed towards the central zone (6) in a first direction (D1), at least a second pushing device for applying, on a second sector (8b) of said plurality, a second force (F2) directed towards the central zone (6) in a second direction (D2), the second direction being arranged transversely to the first direction (D1). The second sector (8b) is in contact with the first sector (8a) for transmitting the second force (F2) to the first sector (8a), so that the forming surface (11 ) of the first sector (8a) is moved towards the central zone (6) under the combined action of the first force (F1 ) and the second force (F2), in order to reduce the volume of the forming region (4).