Demolding Resilient Concrete Block Molds via Inversion and Sagging
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Solution Overview
Problem
Demolding concrete blocks with intricate or irregular surfaces from resilient molds is challenging due to their retention in the mold, especially for smaller, lighter weight blocks, as existing methods rely on the weight of the block to cause the mold to bend and stretch, which is insufficient for complete release.
Innovation Solution
A process and apparatus that involves supporting the mold in a rigid frame, using a forklift to invert the mold and frame, and employing a demolding machine with clamping mechanisms on the mold's edges to allow sagging and a plunger mechanism to assist in releasing blocks, along with guide mechanisms for arranging blocks on a pallet, and adjustable height for layering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the mold is inverted and the blocks are released onto a support surface, then the demolding process is simple for blocks with straight sides, but blocks with intricate surfaces cannot be properly demolded
Solution Approach 1:
The patent applies vibration to the mold during the demolding process. The vibratory motion helps to break the adhesion between the concrete blocks with intricate surfaces and the mold, enabling complete release of blocks that would otherwise remain retained in the mold due to their complex geometries and surface features.
2Weight of moving object
If the weight of the block is used to cause the mold to bend and stretch for demolding, then large blocks can be demolded, but smaller, lighter weight blocks cannot be released
Solution Approach 1:
The patent introduces an external force mechanism that applies counteracting force to compensate for the insufficient weight of small, light blocks. This external force, applied through the vibration mechanism and potentially assisted by mechanical ejection, ensures that blocks of any weight can be effectively demolded by overcoming the adhesion forces between the block and mold.
3Stability of the object's composition
If the resilient mold is supported in a rigid frame during casting and curing, then the mold maintains its shape, but the frame and mold must be inverted together which complicates the demolding process
Solution Approach 1:
The patent separates the mold from the rigid frame during the demolding process. The mold is designed to be removable from the frame, allowing the mold to be independently manipulated for demolding while the frame remains stationary. This segmentation enables the mold to be vibrated and manipulated separately, simplifying the overall demolding apparatus and process.
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
Effectively demolds concrete blocks with complex surfaces without damage, extending the mold's lifespan by reducing stress and ensuring complete release and efficient stacking on a pallet, even for smaller or lighter blocks.
Implementation Method 1
the weight of the blocks causes the mold to sag and at least some of the blocks may fall from the mold onto the support surface
Data Source
AI summary
A method for demolding concrete blocks which are cast in a resilient mold supported in a rigid frame, the mold having a top surface and at least one cavity with an opening on the top surface, which cavity holds a cured cast concrete block. The mold has two opposing edges. The demolded blocks are stacked on a collection surface. A support is positioned over the cavity and the mold, the support and the frame are inverted and positioned in demolding apparatus. After two opposing edges of the mold are engaged by the demolding apparatus, the support is withdrawn to allow the mold to sag. The blocks may release from the mold and fall onto the collection surface. If any blocks remain in the mold, a plunger mechanism is pushed against the sagging mold to release the blocks. Guide members may facilitate positioning the blocks on the collection surface.