Adjustable Mold Sidewalls for Drainage Channel Versatility
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Solution Overview
Problem
The existing methods for creating drainage channels require custom molds for each size, depth, thickness, and slope, leading to high costs and labor intensiveness due to the need for multiple molds, which are often used only once, and result in uneven surfaces that affect liquid flow efficiency.
Innovation Solution
An adjustable mold system comprising an interior and exterior mold with movable sidewalls and spacers that can be adjusted to create drainage channels of varying widths, heights, thicknesses, and slopes, allowing for the same mold to be used for different applications by exchanging or adjusting components, reducing the need for multiple custom molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If custom molds are made for each drainage channel size and configuration, then manufacturing precision and adaptability are improved, but device complexity and cost increase
Solution Approach 1:
The mold assembly is designed as a universal system that can create drainage channels of various widths, depths, and configurations through adjustable components. The exterior mold portions can be repositioned along the interior mold, and spacers of different thicknesses can be used, allowing one mold assembly to replace multiple custom molds for different channel sizes and shapes.
Solution Approach 2:
The mold incorporates dynamic, adjustable elements rather than fixed structures. The exterior mold portions can move along the interior mold to different positions, and spacers can be adjusted or replaced to change the mold cavity dimensions. This dynamic adjustability enables the same mold to produce varied drainage channel configurations.
2Adaptability or versatility
If multiple custom molds are manufactured, then adaptability is improved, but loss of substance and cost increase
Solution Approach 1:
A single universal mold assembly replaces the need for multiple custom molds, eliminating the material cost of manufacturing several different mold sets. The adjustable components allow one mold to perform the function of many custom molds, reducing overall material consumption.
Solution Approach 2:
The mold design allows components to be reused and reconfigured for different production runs. Rather than discarding single-use custom molds, the adjustable components are recovered and repositioned to create new mold configurations, reducing material waste.
3Ease of manufacture
If traditional wooden forms are used, then ease of manufacture is improved, but manufacturing precision and surface smoothness deteriorate
Solution Approach 1:
The mold uses inexpensive interior mold portions that can be discarded or replaced easily. These disposable-like components have smooth surfaces that transfer to the drainage channel, achieving high surface precision without the complexity of reusable precision molds. The smooth interior surfaces of the mold portions directly produce smooth channel surfaces.
4Device complexity
If fixed mold configurations are used, then device complexity is reduced, but adaptability deteriorates
Solution Approach 1:
The mold structure incorporates simple dynamic elements that allow adjustment without complex mechanisms. Exterior mold portions can slide or reposition along the interior mold, and spacers can be adjusted or replaced, providing adaptability through simple mechanical movements rather than complex adjustable systems.
Solution Approach 2:
The mold is divided into separate, modular segments including interior mold portions, exterior mold portions, and spacers. This segmentation allows individual components to be independently adjusted or replaced to create different channel configurations, providing adaptability through modular assembly rather than a fixed monolithic structure.
Data Source
AI summary
Embodiments of the present invention allow for the manufacture of a number of drainage channels of different heights, widths, thicknesses, shapes, and slopes from only one mold or a greatly-reduced number of molds. In one embodiment, the drainage channel mold has an interior mold and an exterior mold. The exterior mold has two opposing sidewalls that can be placed at different distances apart from one another to vary the overall width of the drainage channel. The sidewalls can be independent of each other or they can be coupled to each other yet still allowed to be positioned at different distances apart. In one embodiment, the sidewalls are hingedly coupled to a base support mechanism. The mold also contains mold spacers that can be located between the interior mold and the exterior mold sidewalls to create different heights, widths, shapes, and slopes in the drainage channel walls formed by the adjustable mold.