Integrally Formed Plastic Shim Set for Concrete Panel Construction
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Solution Overview
Problem
The existing shim solutions for concrete panel construction require multiple packs of shims in various thicknesses, leading to high plastic volume and manufacturing inefficiencies, and necessitate on-site availability of multiple shim sizes.
Innovation Solution
A set of integrally formed, one-piece plastic shims with different thicknesses connected by flexible webs, allowing for combination and separation to achieve various thicknesses, and a method of reducing plastic volume through voids in the shim design, such as injection molding with retractable cores, to enhance manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple packs of shims with different thicknesses are supplied separately, then a range of different packing thicknesses can be achieved, but the device complexity and inventory requirements increase
Solution Approach 1:
Multiple shims of different thicknesses (1mm, 2mm, 3mm) are integrally formed as a one-piece plastic moulding, connecting them in adjacent relationship. This merging of multiple separate shim packs into a single integrated unit reduces inventory complexity while maintaining the ability to achieve various packing thicknesses by separating or combining individual shims.
Solution Approach 2:
The integrated shim set is designed with connections that permit individual shims to be separated from the set. This segmentation allows users to obtain individual shims of 1, 2, and 3mm thicknesses or combine them to achieve 4mm, 5mm, or 6mm thicknesses, providing versatility without requiring separate inventory packs.
2Strength
If thick shims of 10 mm and above are manufactured with solid plastic, then structural strength is maintained, but the volume of plastic and manufacturing cost increase
Solution Approach 1:
The thick shim (10mm and above) is moulded with voids extending from at least one edge into the interior, creating a porous structure that reduces plastic volume and cost. The voids are arranged with solid lands between them, maintaining structural integrity while significantly reducing material consumption compared to solid plastic shims of the same thickness.
Solution Approach 2:
The shim employs a composite structure combining solid plastic regions (lands) and void spaces. This composite approach maintains adequate structural strength for supporting concrete panels while reducing the overall volume and cost of plastic material required, particularly for thick shims where material reduction is most beneficial.
3Strength
If thick shims are manufactured with solid plastic, then manufacturing strength is adequate, but the manufacturing cycle time increases
Solution Approach 1:
The voids in the thick shim structure facilitate more efficient cooling during injection moulding, as coolant can flow through the hollow interiors of retractable cores. This porous manufacturing approach reduces manufacturing cycle time while maintaining adequate strength through the strategic placement of solid lands that provide structural support.
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 solution reduces the need for multiple shim packs, decreases plastic usage, and allows for flexible on-site thickness adjustments, improving manufacturing efficiency and reducing costs while maintaining adequate support for concrete panels.
Implementation Method 1
the cores having hollow interiors subject to flow of coolant liquid
Data Source
AI summary
A shim set comprising at least two shims of different thickness, the shims of the set being integrally formed as a one-piece plastic moulding, the shims of the set being connected in adjacent relationship by a connection which permits an individual shim to be separated from the set but which is flexible to permit a shim while connected to an adjacent shim to be folded over so that the two shims lie in face-to-face relation and thereby form a shim combination of increased thickness.