Foam Negative Mold Machining for Manhole Channel Base Sections
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Solution Overview
Problem
Existing methods for producing molds for manhole base pieces with channels are energy-intensive, costly, and pose health risks due to the use of meltable wax-like materials, thermoplastic foams, and wood or plaster processing, which require significant energy, material, and occupational safety measures to manage harmful vapors and dust.
Innovation Solution
A method involving the machining of a base body made of foam material, such as polystyrene, to create a negative mold for the channel structure, which can be precisely worked into a single piece without the need for assembling individual branches, and is processed using techniques like milling, with surface treatment to prevent liquid penetration and improve surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a negative mold is produced from meltable wax-like base body using a heated cutting tool, then the mold can be produced with complex channel structures, but a considerable amount of energy is required both to cut the negative geometry and to reuse residual materials by melting the material
Solution Approach 1:
The patent changes the material parameter from wax-like base body to foam material base body, which can be processed at ambient temperature without melting, thereby eliminating the energy-intensive heating and melting operations while maintaining the ability to produce complex negative geometries through mechanical cutting or milling
Solution Approach 2:
The patent replaces the thermal processing system (heated cutting tool and melting operation) with a mechanical processing system (milling or cutting tools operating at ambient temperature), thereby reducing energy consumption while achieving the same negative geometry formation objective
2Adaptability or versatility
If individual channel branches are cut out separately from the base body and individually joined together and fastened to a base plate, then the channel structure can be produced, but a relatively large amount of time and personnel is required
Solution Approach 1:
The patent merges the entire channel structure into a single integrated negative mold produced from one foam material base body, eliminating the need to cut and join individual channel branches separately. This single-piece construction maintains adaptability for different channel configurations while dramatically improving production efficiency by reducing assembly operations
Solution Approach 2:
The patent performs preliminary action by designing and producing the complete negative mold as a single integrated component from the beginning, rather than assembling it from separate parts. This preliminary integration of the channel structure eliminates subsequent assembly steps and reduces production time and personnel requirements
3Manufacturing precision
If a negative mold is produced from thermoplastic foam by cutting individual channel branches with a heated wire and then joining them together on a plate, then the mold can be formed, but separate cutting operations for each channel branch including clamping and aligning are required
Solution Approach 1:
The patent combines all channel branches into a single integrated negative mold structure, eliminating the need for separate cutting and joining operations for each branch. This approach maintains dimensional accuracy while significantly simplifying the processing operations by reducing the number of clamping and aligning steps required
4Manufacturing precision
If a base body made of wood or plaster is processed by milling to form a negative mold including the entire base contour, then the mold can be produced, but a relatively large amount of material is required and a large amount of effort for milling is needed
Solution Approach 1:
The patent changes the material parameter from wood or plaster to foam material, which has lower density and can be more efficiently milled. This parameter change reduces material consumption while maintaining the ability to produce precise negative mold contours through milling operations
Solution Approach 2:
The patent employs foam material as a disposable or limited-reuse base body that can be efficiently milled and discarded or reused after a limited number of cycles. This approach reduces material costs compared to expensive materials like wood, especially for applications where the negative mold has a limited service life or can be easily replaced
5Manufacturing precision
If molds are produced using known methods, then the channel structure can be formed, but special occupational safety measures are necessary to manage harmful vapors from hot plastic or fine calcium sulphate dust from plaster milling
Solution Approach 1:
The patent changes the material parameter from thermoplastic foam or plaster to cross-linked foam material, which does not release harmful vapors when milled at ambient temperature. This parameter change eliminates occupational health risks associated with vapor inhalation and fine dust exposure while maintaining the ability to produce accurate negative molds through milling operations
Solution Approach 2:
The patent converts the potential harm of material processing by selecting a foam material that produces harmless chips instead of harmful vapors or fine dust. This material selection transforms the processing operation from a hazardous process requiring special safety measures into a safe process that can be performed without special occupational safety precautions
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 reduces energy and material costs, eliminates health hazards by avoiding harmful vapors and dust, and enables efficient production of molds with complex channel structures, while ensuring safety and cost-effectiveness.
Implementation Method 1
a base body made of a foam material, in particular a foamed plastic, is processed by a milling tool (28)
Data Source
Figure 1~3
Figure 4~6
Figure 7a~8
AI summary
The invention provides a method for producing a mold (56) for the manufacture of shaft base pieces (42) having a channel, comprising the steps: providing a base body (14) made of a mixture comprising a sand material and a binding agent, or of a foam material, Machining of the base body (14) in at least one channel section corresponding to the negative geometry of the channel to be manufactured, so that a negative mold (30, 38) is created, inserting the negative mold (30, 38) in a base mold (54).