Adjustable Stair Forming Apparatus with Reconfigurable Units
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Solution Overview
Problem
Traditional stair forming methods using concrete or similar settable materials require multiple molds for different stair configurations, leading to high costs and inefficiencies due to the need for new molds for each design, with existing technologies limiting adjustability in tread length, riser height, nosing, and stair pitch, making them inflexible and costly.
Innovation Solution
An adjustable stair forming apparatus with reconfigurable forming units that can pivot and translate to accommodate varying stair dimensions, allowing for adjustments in the number of stairs, riser height, tread depth, stair width, landing size, and stair angle, with adjustable nosing and flexible membrane support for tension adjustment, enabling the formation of diverse stair shapes from a single apparatus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional fixed molds are used for each stair configuration, then manufacturing precision is maintained, but device complexity and cost increase due to requiring multiple molds
Solution Approach 1:
The mold is divided into multiple adjustable segments including tread forming members, riser forming members, and frame components that can be independently positioned and configured. Each segment can be adjusted to create different stair configurations, eliminating the need for multiple complete molds.
Solution Approach 2:
The mold transitions from a static fixed structure to a dynamic adjustable structure. The tread forming members can pivot about axes, the riser forming members can be repositioned, and the frame components can be adjusted to accommodate varying stair dimensions, allowing one mold to perform multiple functions.
2Adaptability or versatility
If adjustable mechanisms are added to allow different stair configurations, then adaptability improves, but device complexity and portability worsen
Solution Approach 1:
The mold is designed as a universal system where the same basic components (tread forming members, riser forming members, frame) can be configured to create multiple different stair types. The adjustable mechanisms allow a single mold to serve multiple purposes rather than requiring specialized molds for each stair configuration.
Solution Approach 2:
The mold allows adjustment of key parameters including tread length, riser height, stair width, and nosing dimensions. By changing these parameters through adjustable mechanisms, the same mold can produce various stair configurations to meet different architectural requirements.
3Ease of manufacture
If wood molds are used to reduce cost, then manufacturing cost decreases, but reliability and durability worsen due to wear and tear
Solution Approach 1:
The mold employs composite construction combining a metal frame structure with wooden or alternative forming surfaces. The metal frame provides structural strength and durability, while the forming surfaces can be made from various materials including wood, plastic, or metal depending on the specific application requirements.
Data Source
Figure 1a~1b
Figure 2
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AI summary
The invention relates to an adjustable stair forming apparatus, adapted to form a flight of stairs of a settable material. The filght of stairs including a series of treads interconnected by intermediate risers. The apparatus comprises, a frame to support a series of forming units provide a forming surface. Each forming unit, includes a tread defining formwork that includes a rectangular shaped tread forming surface, slidably and pivotally mounted to the frame from or toward a first major edge of the tread forming surface. The forming unit also has a riser defining formwork that includes a rectangular shaped riser forming surface with a first major edge adjustably mounted from or toward the opposite major edge of the tread forming surface. The riser forming surface at least in part co-extending with the tread forming surface in a stair width direction. The forming units each adjustably held in an array to the frame with a bearing surface of one forming unit supported by a tread forming surface of the adjacent forming unit.