Plank forming systems

Abstract

A method or device for creating a plank. The device may include a container with an opening to receive a material. The device may also include a beam extending from a side of the container to a point in an open space of the container. The beam may have a curved shape. A portion of the material may form around the beam.

1 . A system, comprising:
 a first container comprising:
 a first opening to receive a material; and 
 a second opening to provide the material into a second material; 
   a second container, comprising:
 a third opening at a first end of the second container to receive the material from the second opening of the first container; 
 a fourth opening at a second end of the second container; 
 a screw to move the material from the third opening to the fourth opening; and 
 a heater to heat the material to a first temperature to liquefy the material into a liquid material; and 
   a mold device, comprising:
 a third container with a fifth opening to receive the liquid material; 
 a first beam extending from a side of the third container to within an open space of the third container, wherein:
 the first beam is a curved shape; and 
 a first portion of the material forms around the first beam; 
 
 a second beam located along a first edge of the third container, wherein a second portion of the material forms around at least a portion of the second beam; and 
 a third beam located along a second edge of the third container, wherein a third portion of the material forms around at least a portion of the third beam, wherein when the liquid material cools to a second temperature, the liquid material solidifies into a plank. 
   
     
     
         2 . The system of  claim 1 , wherein the first beam forms a curved shaped channel within a middle portion of the plank. 
     
     
         3 . The system of  claim 1 , wherein the second beam forms a first indent along a first edge of the plank. 
     
     
         4 . The system of  claim 1 , wherein the third beam forms a second indent along a second edge of the plank. 
     
     
         5 . The system of  claim 1 , wherein the curved shape is an hourglass shape. 
     
     
         6 . The system of  claim 1 , wherein the curved shape of the first beam forms a curved shape core in the plank to reduce a weight of the plank and increases a weight to load distribution ratio of the plank. 
     
     
         7 . The system of  claim 1 , wherein the curved shape of the first beam is an oval shape, an oval shape with an indent, a square shape with an indent or a circle shape with an indent. 
     
     
         8 . The system of  claim 1 , further comprising a fourth beam located within the open space of the third container, wherein:
 the fourth beam is the curved shape; and   a fourth portion of the material forms around the fourth beam.   
     
     
         9 . The system of  claim 1 , further comprising a cooling tank to reduce a temperature of the plank to a third temperature. 
     
     
         10 . The system of  claim 1 , wherein the mold device receives the material at a defined pressure. 
     
     
         11 . A device, comprising:
 a container with an opening to receive a material; and   a first beam extending from a side of the container to a first point in an open space of the container, wherein:
 the first beam is a curved shape; and 
 a first portion of the material forms around the first beam. 
   
     
     
         12 . The device of  claim 11 , wherein the material is a liquid material and wherein the material cools to a defined temperature, the material solidifies into a plank around the first beam and walls of the container. 
     
     
         13 . The device of  claim 11 , further comprising a second beam located along a first edge of the container, wherein a second portion of the material forms around at least a portion of the second beam. 
     
     
         14 . The device of  claim 11 , further comprising a third beam located along a second edge of the container, wherein a third portion of the material forms around at least a portion of the third beam. 
     
     
         15 . The device of  claim 11 , wherein the curved shape is an hourglass shape. 
     
     
         16 . The device of  claim 11 , further comprising a second beam with the curved shape extending from a side of the container to a second point in the open space of the container. 
     
     
         17 . The device of  claim 11 , wherein the material is at least one of a granulated bamboo fiber or a granulated wood fiber. 
     
     
         18 . The device of  claim 11 , further comprising a vacuum to remove bubbles from the material. 
     
     
         19 . A method, comprising:
 receiving a material in a cavity through an opening in a mold head;   forming the material around a curved beam and walls of the cavity; and   applying pressure and heat to the material to solidify the material into a plank.   
     
     
         20 . The method of  claim 19 , wherein the curved beam is an hourglass shape that creates an hourglass core in the plank.