Molding Device for Swimming Pool Shell with Integrated Roller Shutter Compartment

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Solution Overview

Problem

The manufacturing of swimming pool shells incorporating a compartment for a submerged rolling shutter faces challenges such as material waste, complex installation, and costly mold production, as well as the need for additional assembly inserts and prolonged installation times due to existing techniques.

Innovation Solution

A molding device comprising a conventional shell mold with a removably attached undercut mold allows for the production of a monocoque swimming pool shell with an integrated accessory housing compartment, ensuring a seamless and cost-effective manufacturing process without the need for additional connection elements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a prefabricated module is attached to the pool shell after manufacturing, then the roller shutter compartment can be integrated, but material waste increases due to cutting the main shell and additional lamination is required at the joint

Engineering Contradiction:

Improveintegration of roller shutter compartmentVSAvoidmaterial waste from cutting and additional lamination

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The recess for the roller shutter compartment is created during the initial molding of the pool shell, before the pool is assembled and installed. This preliminary formation of the compartment recess eliminates the need for subsequent cutting operations and additional lamination work, thereby preventing material waste while ensuring proper integration of the roller shutter compartment.

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If the main shell is cut to install an add-on module, then the roller shutter compartment can be added, but installation complexity increases and structural integrity is compromised

Engineering Contradiction:

Improveintegration of roller shutter compartmentVSAvoidinstallation complexity and structural weakening

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The recess for the roller shutter compartment is pre-formed during the molding process of the main shell, eliminating the need for complex on-site cutting and assembly operations. This preliminary action simplifies installation while maintaining the structural integrity of the shell, as no cutting or joining operations are required after manufacturing.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If assembly inserts with bolts are used to seal the joint between shell and module, then watertight sealing can be achieved, but installation time is prolonged and additional components are required

Engineering Contradiction:

Improvewatertight sealingVSAvoidinstallation time for positioning inserts and bolting

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The recess for the roller shutter compartment is integrated into the main shell as a single molded piece, combining the shell and compartment into one unified structure. This merging eliminates the need for separate assembly inserts, bolts, and sealing operations, thereby reducing installation time while maintaining watertight integrity through the continuous lamination of the monoblock structure.

Inventive Principle:

Principle #5Merging (Combining)

4Adaptability or versatility

If multiple molds are produced for different module positions, then customizations can be accommodated, but manufacturing cost and production time increase significantly

Engineering Contradiction:

Improvecustomization for different module positionsVSAvoidmanufacturing cost and production time

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

A single universal mold is designed with the capability to form recesses at various positions on the pool shell. This multi-functional mold can accommodate different customization requirements for roller shutter compartment positions without requiring multiple specialized molds, thereby reducing manufacturing costs and production time while maintaining adaptability to customer specifications.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP3546168B1Device for moulding a shell for a monoshell pool basin

Publication Date: 2020.05.27 COMPOSITE IND DU PERIGORD

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AI summary

The invention relates to a molding device (1) for a swimming pool shell, which incorporates an accessory housing compartment. The device (1) comprises a hollow base mold (4) and at least one undercut mold (5) having an interface face adapted to be placed against one (42) of the lateral walls of the base mold (4), and a molding face having a profile conforming to the interior of said compartment, the at least one undercut mold (5) being adapted to be temporarily attached to the base module (4) by removable connecting means. The invention also relates to a method for manufacturing a swimming pool shell using such a device (1) and a shell thus obtained.