Movable End Wall Mold for Tapered Masonry Units
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Solution Overview
Problem
Existing methods for producing tapered concrete masonry units are complex, costly, and prone to unit damage or deformation due to the difficulty in removing molded composite material from molds with angled side walls, such as tilt-over, retractable, and hinged wall techniques.
Innovation Solution
A mold design featuring movable end walls with a groove and pivot elements that can slide and rotate, allowing for easy formation and demolding of tapered products without external power or control devices, using a pallet to force the movable walls into position and allowing gravity to facilitate movement during demolding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If tilt-over molds are used to create tapered masonry units, then the tapered shape can be formed, but the machinery becomes complex and production time increases
Solution Approach 1:
The mold wall is designed to be movable rather than fixed, allowing it to transition between angled and vertical positions. This dynamic structure enables the same mold to produce tapered units during formation and then be repositioned for easy removal, eliminating the need for complex tilt-over machinery while maintaining the tapered shape capability
Solution Approach 2:
The mold wall is divided into separate components that can move independently - a movable wall assembly that can be positioned at angles during filling and then repositioned after curing. This segmentation allows the tapered shape to be formed without requiring the entire mold structure to be complex or require special tilt-over mechanisms
2Shape
If retractable walls are used to form tapered masonry units, then the tapered shape is achieved, but the machinery becomes bulky and requires separate power and controls
Solution Approach 1:
The movable wall assembly is designed to be self-positioning through its mechanical connection to the pallet and gravity. The wall automatically moves into the correct angled position during filling without requiring external power or control systems, and can be easily repositioned after curing. This eliminates the need for bulky hydraulic or pneumatic systems while achieving the tapered shape
Solution Approach 2:
The movable wall is positioned and held in place using gravity and the pallet structure, creating a system where components are in equilibrium without requiring additional power sources. The wall naturally remains in the angled position during filling and can be easily repositioned afterward, eliminating the need for separate power and control systems
3Shape
If hinged walls are used to create tapered masonry units, then the angled position can be achieved, but the walls may pivot out of position during vibrating and the tapered walls become deformed
Solution Approach 1:
The movable wall is pre-positioned in the correct angled orientation before the vibrating and curing steps. The wall is mechanically secured in this position through its connection to the pallet and mold structure, ensuring it remains stable during vibration and does not pivot out of position. This preliminary positioning action prevents deformation of the tapered walls while maintaining the desired angled shape
4Shape
If special molds are used to create tapered masonry units, then the tapered shape can be formed, but stripping the molded composite material becomes difficult
Solution Approach 1:
The movable wall is designed to be easily repositioned after the molded unit is formed. After curing, the wall can be quickly moved from its angled position to a vertical position, allowing the molded unit to be easily stripped from the mold. This dynamic repositioning capability maintains the tapered shape during formation while making removal simple and efficient
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
Enables simple, automatic, and cost-effective production of high-quality tapered masonry units with reduced production time and minimal risk of damage, as the movable end walls remain stable during vibration and demolding, allowing for efficient clearance of residual material and faster cycle times.
Implementation Method 1
the movable element is rotatably attached to the pivot element such that the movable element is capable of moving between an angled position and a vertical position
Implementation Method 2
the movable element is slidably and rotatably attached to the groove of the stationary element
Implementation Method 3
allowing gravity to facilitate movement during demolding
Data Source
AI summary
The present invention relates to an apparatus and method for forming molded tapered products, such as masonry blocks, whereby high quality finished products are removed from their mold without the need for complex machinery for demolding. The mold may include one or more mold cavities having one or more movable cavity walls. The movable cavity walls may include an end liner having a planar product forming surface capable of moving from a vertical position to an angled position. Tapered products may be formed by moving the mold towards a pallet so that the pallet engages with the end liner and causes the end liner to move from the vertical position to the angled position. Moldable material may then be introduced into the mold cavity and may be allowed to remain in the mold cavity until it is self-sustaining.