Reversible Sprinkler Mold Assembly for Concrete Wall Installation
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Solution Overview
Problem
Existing sprinkler piping molds for concrete walls are inefficient due to high labor and time requirements for assembly and disassembly, lack of sturdiness, and difficulty in reuse, as well as unnecessary components that increase costs and complexity.
Innovation Solution
A sprinkler mold assembly with a reversible insert and unitary cover that can be mounted in either direction, featuring a cylindrical surface with fastener passages and a tool engagement surface for easy assembly and disassembly, reducing the number of components and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a one-piece mold is used, then the mold structure is simple, but the fastening members must be pulled or cut to separate the mold from the concrete form, increasing labor and time requirements
Solution Approach 1:
The mold is divided into two separate pieces: a bell-shaped member and a flat plate. The flat plate remains attached to the concrete form after disassembly, while the bell-shaped member can be easily removed. This segmentation eliminates the need to pull or cut fastening members, significantly reducing disassembly time and labor while maintaining structural simplicity.
2Ease of operation
If fastening members are made removable to allow separation, then the mold can be detached from the concrete form, but the connection security is compromised
Solution Approach 1:
The mold system is segmented into a removable bell-shaped member and a permanent flat plate component. The flat plate is designed to remain securely attached to the concrete form through embedded fastening members, providing reliable connection security. The bell-shaped member can be easily detached by removing its fastening members, providing ease of operation. This segmentation resolves the contradiction by assigning different functional roles to different components.
3Ease of operation
If a two-piece mold is used, then access to the pipe is easier after form removal, but the bottom piece walls are likely to be deformed or damaged, providing inadequate connection and prohibiting reuse
Solution Approach 1:
The mold is segmented into a bell-shaped member and a flat plate, where the flat plate is designed as a durable, damage-resistant component that remains attached to the concrete form. The bell-shaped member is the component that is removed and replaced, protecting the durable flat plate from deformation and damage. This segmentation allows pipe accessibility while preserving mold durability and reusability.
Solution Approach 2:
The bell-shaped member is designed as a disposable or replaceable component that can be damaged or lost during construction. Since it is relatively simple in structure and lower cost, it can be replaced if damaged. The expensive, durable flat plate with embedded fastening members remains permanently attached to the concrete form, ensuring long-term connection security and reusability.
4Adaptability or versatility
If multiple components are used in the mold, then the functionality is enhanced, but the number of components increases, increasing costs and complexity
Solution Approach 1:
The mold is segmented into exactly two functional components: a bell-shaped member and a flat plate. This minimal segmentation provides the necessary functionality (displacement, attachment, and accessibility) without excessive complexity. The segmentation allows the mold to perform multiple functions while maintaining a simple component structure that is easy to assemble, install, and maintain.
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3C
AI summary
A two-component mold assembly for molding an opening within a concrete wall that provides access to a piping system supporting a sprinkler. The first component is an insert that is mounted on a concrete form, and the second component is a cover that slidably fits over the insert to define the opening in the concrete. The cover plugs the piping system during fabrication of the concrete wall and is removeable from the opening in the hardened concrete after the concrete form and the mounted insert are removed.