Interconnected Filler Boxes for Two-Layer Concrete Block Molding

Solution Overview

Problem

The existing molding process for ornamental casted units, which involves a base layer of coarser concrete and a surface layer of finer decorative concrete, faces issues with delamination and increased production cycle duration due to the need for a second cycle of compression and vibration after adding the face mix, limiting the number of production runs that can be performed in a given period.

Innovation Solution

A casted block molding apparatus and method that uses interconnected filler boxes to sequentially distribute a base granular mixture and a facing granular mixture into mold cavities, with the facing mixture being deposited over the base mixture during the same displacement cycle, and then compressed together to form the blocks, eliminating the need for additional compression cycles and reducing the risk of delamination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a second cycle of compression and vibration is applied after adding the face mix, then the bonding between layers is improved, but the molding cycle duration increases

Engineering Contradiction:

Improvebonding between layersVSAvoidmolding cycle duration

Core Design Contradiction:

ReliabilityVSDuration of action of moving object

Solution Approach 1:

The base mix is compacted and a smooth surface is created before the face mix is added. This preliminary compaction ensures proper bonding conditions are established in advance, eliminating the need for a second compression cycle after face mix addition.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The face mix is added immediately after the base mix compaction while the mold is still in position and the material is in a receptive state. This continuous process eliminates idle time and the need for additional compression cycles, maintaining production efficiency.

Inventive Principle:

Principle #20Continuity of useful action

2Reliability

If a second cycle of compression and vibration is applied after adding the face mix, then the bonding between layers is improved, but the production efficiency decreases

Engineering Contradiction:

Improvebonding between layersVSAvoidproduction efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The base mix is compacted and a smooth surface is created before the face mix is added. This preliminary compaction ensures proper bonding conditions are established in advance, eliminating the need for a second compression cycle after face mix addition.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The face mix is added immediately after the base mix compaction while the mold is still in position and the material is in a receptive state. This continuous process eliminates idle time and the need for additional compression cycles, maintaining production efficiency.

Inventive Principle:

Principle #20Continuity of useful action

3Device complexity

If the filler boxes are designed to distribute both mixes simultaneously, then the process complexity is reduced, but the risk of mixing errors increases

Engineering Contradiction:

Improveprocess complexityVSAvoidmixing accuracy

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The filler system is divided into two separate filler boxes - one for base mix and one for face mix. Each box has its own discharge mechanism and timing control, allowing independent operation and precise control over when each material is added, preventing mixing errors.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The filler boxes are designed with movable covers that can be dynamically opened and closed at specific moments in the cycle. The base mix filler box operates first, then the face mix filler box is activated, creating a dynamic sequential filling process that simplifies the overall system while maintaining reliability.

Inventive Principle:

Principle #15Dynamics

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 the molding cycle duration, allows for the same cycle time for both single and two-layer blocks, and minimizes the risk of delamination by ensuring thorough intermingling of the components, thereby increasing production efficiency and consistency in the finished product.

Implementation Method 1

distributing the base granular mixture from the first filler box to fill the mold cavities

Methodology Applied

Scientific EffectGravity: Gravitation

Implementation Method 2

pressing downwardly on the facing and base granular mixtures in the mold cavities to shape the casted blocks

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS10500758B2Casted block molding apparatus and method

Publication Date: 2019.12.10 TECHO BLOC INC

AI summary

A casted block molding apparatus, including a mold, first and second filler boxes, and a pressing mechanism. The first filler box is displaceable along opposed directions between an overlapping position where a first bottom opening is located over the mold cavities and a retracted position away from the mold cavities. The first bottom opening is closed by a first cover in the retracted position and is open over the mold cavities. The second filler box is mounted to the first filler box and displaceable therewith along the opposed directions. The bottom opening of the second filler box is closed by a second cover when the filler boxes are displaced from the retracted position to the overlapping position. The second bottom opening is open after the first filler box reaches the overlapping position. A method for molding casted blocks is also discussed.