Vacuum Deformable Mold for Architectural Concrete Shaping
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Solution Overview
Problem
Existing molding technologies face challenges in creating decorative patterns with consistent thickness and preventing material flow during the molding process, especially when molding complex shapes for architectural or civil engineering applications.
Innovation Solution
A molding device comprising an envelope with a vacuum connection and a deformable mold, where deformation members stress the envelope to conform the mold to a desired shape, ensuring the material remains of constant thickness and preventing air bubbles that could lead to surface defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid mold is used for molding complex shapes, then the structural strength is improved, but the ability to conform to complex decorative shapes deteriorates
Solution Approach 1:
The mold is made flexible by covering a rigid support structure with a flexible material such as rubber or silicone rubber. This flexible shell can conform to complex decorative shapes while the rigid support underneath provides structural strength. The flexible material allows the mold to be deformed by deformation members to achieve various decorative patterns while maintaining sufficient structural integrity during the molding process.
2Shape
If the mold is deformed to create complex shapes, then the aesthetic shape capability is improved, but material flow and thickness consistency deteriorate
Solution Approach 1:
A vacuum is applied to the envelope containing the mold before and during the deformation process. This vacuum creates a counteracting force that holds the flexible mold against the rigid support structure, preventing the mold from deforming in an uncontrolled manner. This preliminary anti-action ensures that when deformation members are activated, the mold deforms uniformly without causing material flow or thickness variations in the concrete mixture.
3Object-affected harmful factors
If air is removed from the mold cavity, then surface quality is improved, but material pumping and air bubble entrapment deteriorate
Solution Approach 1:
A flexible membrane is placed between the vacuum source and the concrete mixture in the mold cavity. This membrane acts as an intermediary that transmits the vacuum force to the flexible mold walls without directly contacting or pumping the concrete mixture. The membrane allows air to be removed from the envelope and mold cavity to improve surface quality while preventing the vacuum from directly acting on the material, thus avoiding air bubble entrapment and material pumping.
4Device complexity
If a simple envelope structure is used, then device complexity is reduced, but the ability to maintain vacuum and deformation capability deteriorates
Solution Approach 1:
The system is segmented into distinct functional components: a simple envelope structure for containment, a separate flexible mold for shape formation, a vacuum system for maintaining negative pressure, and deformation members for shaping. This segmentation allows each component to be optimized independently - the envelope remains simple while the flexible mold provides both vacuum sealing and deformation capability through its unique dual-function design.
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 allows for the efficient molding of parts with aesthetic shapes, maintaining consistent thickness and preventing material flow, while enabling the creation of complex shapes with reduced risk of defects, such as air bubbles and uneven thickness.
Implementation Method 1
a vacuum connection (16) makes it possible to create a vacuum in the casing (12)
Implementation Method 2
a deformation member (18) makes it possible to deform the mold (14)
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a manufacturing method that comprises the steps of providing an envelope (12) and a mould (14), introducing a moulding material into the mould, placing the mould into the envelope, generating a negative pressure in the envelope, and deforming the mould. The invention also relates to a device for moulding parts. The invention can be used for moulding a part in a simple manner.