Shaft Bottom Lining Molding With Flexible Film for Narrow Access
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Solution Overview
Problem
Current methods for producing shaft bottom linings are time-consuming and labor-intensive, especially when renovating older shafts, as they require complex manufacturing processes and sealing of porous negative molds, which increases costs and renovation duration.
Innovation Solution
A method involving a highly elastically deformable plastic film covering a negative mold made from materials like foamed plastic or metal, allowing for easy removal and molding of a flexible polymer base body with integrated pipe sockets and adhesive bridges, enabling the shaft bottom lining to be bent and inserted through narrow access points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a negative mold is made from foamed plastic and sealed or coated before molding, then the surface of the molded part can be made smooth and the mold can be removed non-destructively, but the manufacturing process becomes time-consuming and expensive
Solution Approach 1:
The patent uses a disposable paper or cardboard mold instead of a reusable sealed mold. The mold is intentionally designed to be destroyed during the molding process, eliminating the need for time-consuming sealing and coating operations. The mold serves its purpose during molding and is then discarded, significantly reducing manufacturing time and cost while still achieving smooth surfaces.
Solution Approach 2:
The patent extracts the sealing and coating steps from the molding process entirely by using a disposable mold that doesn't require these preparatory operations. The mold material itself (paper or cardboard) provides sufficient surface quality without requiring additional sealing layers, thereby eliminating the time-consuming sealing step.
2Ease of manufacture
If a prefabricated plastic shaft bottom lining is inserted into the shaft, then rehabilitation work is simplified, but the lining cannot be inserted through narrow access points without cutting into sections
Solution Approach 1:
The patent creates a dynamic molding process where the polymer material is injected in a liquid or pasty state and then solidifies within the mold. This allows the lining to be produced with optimized geometry that can be inserted as a single piece through narrow access points, eliminating the need for cutting and reassembly operations.
Solution Approach 2:
The patent changes the physical state parameter of the polymer material during molding (from liquid/pasty to solid) to create a lining that can be inserted through narrow access points. The molding process allows the material to flow into the mold in a fluid state and then solidify into the final insertable form, optimizing both manufacturability and installability.
3Ease of manufacture
If the negative mold surface is porous and rough, then the mold can be made simply from foamed plastic, but the molded part surface becomes rough and the mold cannot be removed non-destructively
Solution Approach 1:
The patent uses a disposable paper or cardboard mold that is intentionally designed to be destroyed during the molding process. The simplicity of the mold material (porous paper or cardboard) is acceptable because it is discarded after use, eliminating the need for complex sealing operations while still enabling smooth surface production through the molding process itself.
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 method simplifies the manufacturing process, reduces renovation time and labor, and allows for easier insertion and fixing of the shaft bottom lining, reducing costs and improving the efficiency of shaft renovation.
Implementation Method 1
the film consists of a highly elastically deformable plastic
Implementation Method 2
creating the base body by molding a polymer in a liquid or pasty state onto the surface of the negative mold covered with the flexible film
Data Source
Figure 1~2
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Figure 4~7
AI summary
A method for producing a molded part, in particular a manhole bottom lining (1) for a sewer manhole, with a base body (2) which preferably has a walking surface (3) and at least one pipe connection opening (5), comprises the following process steps: a) creating a negative mold (27) of the molded part, b) at least partially covering the negative mold (27) with a flexible film (36), in particular made of silicone or another elastic material, and c) creating the base body (2) by molding a material in a liquid or pasty state onto the negative mold (27).