Drainage Element Molding with Pressurized Ladle and Lowerable Bottom

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Solution Overview

Problem

Existing methods for producing drainage elements with expanded plastics granulate result in uneven distribution of granulates, leading to cavities and reduced compressive strength, and limit the production of elements to specific thicknesses due to mold constraints.

Innovation Solution

A method and device where the molding compound is pressurized in a ladle and then poured into a mold with a lowerable mold bottom, allowing for uniform packing and adjustable thickness, using a stationary mold setup with lateral displacement of the ladle between multiple molding stations, and varying compression levels to achieve desired strength and reduce material usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the molding compound is dispersed through a nozzle orifice into passing open face molds, then the production efficiency is improved, but the granulates become unevenly distributed resulting in cavities and reduced compressive strength

Engineering Contradiction:

Improveproduction efficiencyVSAvoiduniformity of granulate distribution

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The molding compound is pressurized in advance within the ladle before being poured into the mold. This preliminary pressurization ensures that the granulates are tightly packed and uniformly distributed before the molding process begins, preventing cavity formation during subsequent compression while maintaining high production efficiency

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Instead of allowing the molding compound to flow into the mold under its own pressure (which causes uneven distribution), the invention inverts the approach by pressurizing the compound in the ladle first, then pouring it into the mold. This reversal of the pressure application timing ensures uniform distribution while maintaining productivity

Inventive Principle:

Principle #13The other way round (Inversion)

2Device complexity

If molds with defined depths are used, then the device structure is simplified, but only elements of a given thickness can be produced limiting versatility

Engineering Contradiction:

Improvemold structure simplicityVSAvoidelement thickness variation capability

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The mold bottom is made movable rather than fixed, allowing it to be lowered to different positions to accommodate elements of varying thicknesses. This dynamic adjustment capability enables the same mold structure to produce elements with different thickness requirements while maintaining structural simplicity

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The mold is designed with a movable bottom that can be adjusted to different positions, making it capable of producing elements with various thicknesses. This multi-functional design allows a single mold structure to serve multiple thickness requirements, enhancing versatility without increasing device complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This approach ensures optimal packing of granulates, allowing for the use of expanded granulates with higher bulk density, enabling production of elements with varying thickness and strength without compromising compressive strength, while simplifying the design and reducing material and production costs.

Implementation Method 1

the molding compound is received and pressurized in a ladle having a pouring opening closed off by a mold bottom

Methodology Applied

Scientific EffectPressure: Pressure Increase

Implementation Method 2

the molding compound is poured, by lowering of the mold bottom, down into a mold

Methodology Applied

Scientific EffectGravity: Gravitation

Implementation Method 3

the whole pressure continues to act on the pouring end of the molding compound throughout the molding process

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentEP2531336B1Method and device for producing a drainage element and drainage element produced thereby

Publication Date: 2019.03.27 ISODRAN

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AI summary

A porous hardenable drainage element (14) is produced from a molding compound (10) of expanded plastics granulate and a bonding agent by virtue of the fact that the molding compound is received in a ladle (30) having a pouring opening (32) closed off by a mold bottom (44), the molding compound is pressurized in the ladle, the element (14) is molded from the molding compound in a mold formed by lowering of the mold bottom (44) down into an opening cross section (42) consistent with a cross section of the pouring opening (32), and the element is separated from the molding compound by mutual lateral displacement of the mold and the ladle (30).