Rotating Mold for Noise Barrier Wall Production

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Solution Overview

Problem

Current methods for forming noise absorbing barrier walls face challenges such as large mold size, difficulty in creating aesthetic designs on both sides, and extended curing times, which hinder efficient production and reuse of molds.

Innovation Solution

A mold system that can rotate between vertical and horizontal orientations, allowing for efficient use of space, precise design transfer to both noise absorbing and concrete sides, and faster demolding and erection by curing in a vertical position.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a pan mold with an enlarged horizontal floor is used to form noise absorbing barrier walls, then the materials can harden together, but the mold occupies a large area of space making it difficult to simultaneously produce multiple barrier walls

Engineering Contradiction:

Improveease of forming barrier wallVSAvoidmold area

Core Design Contradiction:

Ease of manufactureVSArea of stationary object

Solution Approach 1:

The mold is oriented vertically instead of horizontally, changing the spatial dimension from horizontal to vertical. This allows the mold to occupy less floor space while maintaining the same production capacity, enabling multiple molds to be arranged in a smaller area.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The mold is designed to be rotatable between vertical and horizontal orientations. This dynamic capability allows the mold to be positioned vertically for space-efficient production and horizontally for design transfer, providing flexibility to resolve the spatial contradiction.

Inventive Principle:

Principle #15Dynamics

2Manufacturing precision

If the concrete side of the barrier wall is openly exposed during forming, then the noise absorbing side can have a design transferred to it, but it is difficult to produce a design on the concrete side

Engineering Contradiction:

Improvedesign transfer precisionVSAvoidease of producing design

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The mold's rotatable design allows it to be positioned horizontally when design transfer is needed, providing stable access for attaching design elements to the concrete side. After design transfer, the mold can be rotated to vertical position for forming, resolving the contradiction between design precision and manufacturing ease.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The design is transferred to the concrete side while the mold is in horizontal position, before the actual barrier wall forming process. This preliminary action ensures the design is properly attached and will be imprinted onto the barrier wall when the mold is rotated to vertical position and concrete is poured.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If barrier walls are left in horizontal orientation to cure, then they can harden properly, but it takes an extended period of time before they can be demolded and erected

Engineering Contradiction:

Improvecuring qualityVSAvoidcuring time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The mold maintains vertical orientation throughout the curing process, allowing barrier walls to be formed and cured in a stable, space-efficient position. The vertical orientation provides structural stability during curing, eliminating the need for extended horizontal curing time and enabling faster demolding and erection.

Inventive Principle:

Principle #15Dynamics

4Area of stationary object

If the mold is in vertical orientation, then space is used efficiently and structural stability is improved, but it is difficult to transfer designs to both sides of the barrier wall

Engineering Contradiction:

Improvemold areaVSAvoiddesign transfer precision

Core Design Contradiction:

Area of stationary objectVSManufacturing precision

Solution Approach 1:

The mold can rotate between vertical and horizontal orientations. It is positioned vertically for space-efficient storage and stable barrier wall formation, then rotated to horizontal position when design transfer is required. This dynamic positioning resolves the contradiction between space efficiency and design transfer capability.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS11400621B2Methods for forming noise absorbing barrier walls and related forms

Publication Date: 2022.08.02 SUPERIOR CONCRETE PRODUCTS LLC

AI summary

A barrier wall is formed by rotating a mold to a horizontal orientation so that a rear wall of the mold is horizontally disposed and an encircling sidewall upstands from the rear wall, the floor and encircling sidewall at least partially bounding a compartment, an upper end of the encircling sidewall at least partially bounding a first access opening to the compartment. A first material is disposed into the compartment through the first access opening, at least a portion of the material being curable. A cover is placed over the first access opening to enclose the compartment. The mold is then rotated from the horizontal orientation to a vertical orientation. A portion of the sidewall is then moved to form a second access opening to the compartment. A second material is then dispensed into the compartment, at least a portion of the second material being curable.