Concrete Spacer Manufacturing via Segmented Mold Casting
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Solution Overview
Problem
Current methods for producing concrete spacers, such as casting and extrusion processes, are inefficient and fail to provide a strong chemical-physical connection with in-situ concrete, leading to potential infiltration of pollutants and limitations in shaping and transportation.
Innovation Solution
A method involving a pre-produced slab-shaped cast concrete block with predetermined breaking points and a mold design that creates a rough outer surface and precise contact areas, allowing for automated production of spacers with broken edges for enhanced interlocking with in-situ concrete, while maintaining smooth surfaces for reinforcement fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional casting process is used to produce spacers, then manufacturing precision and shape definition are improved, but productivity and production efficiency deteriorate due to individual mold requirements and time-consuming procedures
Solution Approach 1:
The mold is divided into a base plate with multiple cavity structures, allowing simultaneous production of multiple spacers. Each cavity acts as an independent molding space, enabling batch production while maintaining individual shape precision.
Solution Approach 2:
Multiple spacer production operations are merged into a single casting process by arranging multiple cavities in one mold. The base plate integrates multiple cavity structures, allowing simultaneous curing of multiple spacers in one operation cycle.
2Manufacturing precision
If conventional casting process is used to produce spacers, then manufacturing precision is improved, but loss of time increases due to required hardening time and sequential production
Solution Approach 1:
The mold structure is segmented into multiple independent cavities that can be filled and cured simultaneously. This parallel processing approach reduces total production time while each cavity maintains precise dimensional control through its defined geometry.
Solution Approach 2:
The base plate with cavity structures is pre-configured before casting, allowing rapid sequential filling of multiple cavities. The predetermined mold structure eliminates setup time for each individual spacer production.
3Ease of manufacture
If smooth outer surface is used on cast spacers, then manufacturing ease is improved, but bond strength with in-situ concrete deteriorates due to limited chemical-physical connection
Solution Approach 1:
The spacer surface is designed with different local properties: the outer surface remains smooth for ease of manufacture and aesthetic purposes, while the lateral bonding surfaces feature roughened structures that enhance chemical-physical bond strength with surrounding concrete.
Solution Approach 2:
The roughened lateral surfaces, which increase manufacturing complexity, are converted into a beneficial feature that significantly enhances bond strength. The increased surface area and roughness create better mechanical interlocking and chemical bonding with in-situ concrete.
4Productivity
If extrusion process is used to produce spacers, then productivity is improved through continuous production, but adaptability deteriorates due to limitations in shaping and retaining element incorporation
Solution Approach 1:
The mold base plate is divided into multiple cavity structures with varying geometries, allowing different spacer shapes to be produced in the same mold. Each cavity can be designed with specific dimensions and features to meet different application requirements.
Solution Approach 2:
The multi-cavity mold base plate serves multiple functions: it can produce different spacer shapes, incorporate various retaining element configurations, and accommodate different cavity sizes. This universal mold design replaces the need for multiple specialized molds.
Data Source
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AI summary
The invention relates to a method for manufacturing concrete spacers. The object of the invention is to produce spacers using cast concrete, at least one mold, and spacer fasteners inserted into the spacers. This is achieved through four process steps. First, a flat concrete slab (1) is produced in a mold. Then, the spacer fasteners (2) are inserted into the open top surface of the cast concrete slab (1). After hardening, the concrete slab is demolded, and finally, a plurality of spacer bodies are produced by mechanically breaking the concrete slab (1).