Stackable Mold Trays for Cementitious Doby Production
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Solution Overview
Problem
Current manufacturing practices for cementitious reinforcing support devices, known as dobies, are labor-intensive and inefficient, requiring significant handling and packaging labor, and do not allow for optimal curing conditions or the production of custom shapes.
Innovation Solution
The use of lightweight, moldable trays with cavities for forming dobies, which are stackable and designed for efficient shipping, filled with a programmable grout mixing and pumping system, allowing for on-site production and curing within sealed boxes, enabling a wide range of shapes and secure embedding of reinforcing materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing practices are used for dobies, then production can occur, but significant handling and packaging labor is required
Solution Approach 1:
The patent combines multiple manufacturing operations (mixing, molding, curing, and packaging) into a single integrated process. The trays are placed directly in packaging boxes at the manufacturing location, and grout is pumped through distribution manifolds to fill multiple trays simultaneously. The boxes serve dual purposes as both packaging containers and curing chambers, eliminating separate handling and packaging steps.
Solution Approach 2:
The manufacturing system is divided into modular components: stackable trays with standardized cavities, collapsible packaging boxes, and a grout distribution system with manifolds. This segmentation allows for efficient stacking and nesting during shipping, while enabling rapid assembly and filling at the manufacturing location. The modular design facilitates the layering process where filled trays are stacked and sealed in boxes for curing.
2Reliability
If traditional manufacturing methods are used, then dobies can be produced, but optimal curing conditions cannot be achieved
Solution Approach 1:
The packaging boxes serve multiple functions: they act as containers for transporting empty trays, as molds during the filling process, as curing chambers providing controlled moisture and temperature environments, and as protective packaging for the finished product. This multi-functionality eliminates the need for separate curing facilities or equipment, achieving optimal curing conditions without increasing overall system complexity.
3Adaptability or versatility
If traditional manufacturing approaches are used, then production can occur, but on-site production is not enabled
Solution Approach 1:
Empty trays are pre-formed and shipped to the manufacturing location in nested or stacked configurations. The packaging boxes are prepared in advance and placed on pallets. When production is needed, the trays are simply placed in the boxes and grout is pumped through the distribution system. This preliminary preparation enables rapid on-site production without requiring complex setup procedures, achieving both adaptability and productivity.
4Adaptability or versatility
If custom shapes are produced, then versatility is improved, but manufacturing complexity increases
Solution Approach 1:
The tray system uses standardized tray designs with cavities that can be configured in different patterns and arrangements. Custom shapes are achieved by varying the cavity layouts within the trays rather than designing entirely different mold systems. The grout distribution manifolds can be adjusted to accommodate different tray configurations. This approach enables production of various custom-shaped dobies while maintaining relatively simple, standardized manufacturing equipment.
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 significantly reduces manufacturing labor, allows for efficient handling and shipping, and provides optimal curing conditions, enabling the production of various shapes and secure reinforcement, thus improving the efficiency and versatility of dobie manufacturing.
Implementation Method 1
The grout mixing and pumping machine produces a time programmable stream of grout. A cycle to fill a tray is initiated using a trigger located at the discharge nozzle by the machine operator. The operator triggers the cycle, grout is produced at the machine and pumped to the nozzle and into the tray
Implementation Method 2
The lids of the boxes are then closed and sealed, trapping and retaining moisture within the boxes. This creates an optimum curing condition.
Implementation Method 3
This allows for curing of the dobies within the box in a moist environment. This provides an optimum curing condition for the dobies.
Data Source
AI summary
Lightweight trays are fabricated containing a multitude of cavities in shapes for molding dobies for supporting concrete reinforcing, such as rebar. The trays are sized to fit boxes of a convenient size and weight. The trays are also designed in a way that when placed into the box they make a seal between the tray edges and the inside wall of the box. This seal allows the cavities in the tray to be filled with grout without spilling into a lower tray. The trays are also designed so that when placed into the box and turned, alternating 180° to each other, the lower tray provides support to the upper tray. The boxes are sealed and the dobies are allowed to cure inside the box. The size and arrangement of trays and boxes is designed to fit uniformly on a standard pallet for convenient handling, storage, and shipping.