Retaining Wall Block Mold Segmentation for Faster Curing
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Solution Overview
Problem
The lengthy curing time of retaining wall blocks made from concrete or rebar reinforced concrete in traditional molds reduces productivity, as blocks cannot be separated and reused until fully cured, often requiring several hours or even days, which limits the throughput of block production.
Innovation Solution
A mold design featuring a movable bottom tray and a mold housing with a door system that allows for the separation of blocks when they are only partially cured, enabling them to cure independently while the mold is reused for subsequent blocks, thereby reducing overall production time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If blocks are kept in the mold until fully cured, then the blocks achieve sufficient strength and structural integrity, but the production time increases significantly and mold productivity decreases
Solution Approach 1:
The mold is segmented into a stationary housing and a movable bottom tray assembly. This segmentation allows the tray with the partially cured block to be separated from the housing, enabling the housing to be immediately reused while the block continues curing externally. This resolves the contradiction by decoupling the mold availability from the full curing time requirement.
Solution Approach 2:
The block is allowed to cure to a preliminary sufficient state within the mold before removal. This preliminary curing provides enough structural integrity for the block to be handled and continue curing independently, allowing the mold to be reused sooner while still achieving full strength development.
2Ease of operation
If the mold structure is simplified for easier operation, then the block removal process becomes faster, but the structural integrity and precision of the mold may be compromised
Solution Approach 1:
The bottom tray is designed as a movable component that can be shifted horizontally relative to the stationary housing. This dynamic feature allows easy removal of the tray with the block through the side opening, while the overall mold structure maintains its structural integrity through the robust connection between the tray and housing.
Data Source
AI summary
Embodiments of a mold for making a retaining wall blocks are disclosed. The mold enables blocks to be made more quickly by enabling separation of each block from the mold housing when the block is cured sufficiently to enable separation. Once separated, the block can be permitted to fully cure away from the mold housing, while the mold housing is re-used to produce one or more other blocks. In one embodiment, among others, the mold has a movable bottom tray and a mold housing with at least one door. The mold housing has an opening designed to receive and introduce a fabrication material, such as concrete, into the cavity. Once a block is sufficiently cured, it is separated from the mold housing on the tray through the at least one door, and a new tray is inserted in the mold housing to make another block.