Truncated Cone Moulding Insert for Concrete Facing Blocks
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Solution Overview
Problem
The existing methods for manufacturing and transporting moulding inserts for attaching fill reinforcements to concrete facing blocks in civil-engineering structures are complex and inefficient, with high void fractions in transport and potential premature degradation of reinforcements due to concrete contact.
Innovation Solution
A moulding insert comprising a shell and a core envelope, where the core envelope is in the form of a truncated cone, allowing for compact stacking and easy assembly to form a cavity for reinforcement connection, reducing void fraction and preventing concrete ingress, while providing mechanical strength and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional moulding inserts are manufactured and transported separately, then the manufacturing process is simple, but the void fraction in transport packages is high and transportation costs increase
Solution Approach 1:
The core envelope is inserted inside the shell to form an integrated moulding insert. The core envelope contains the reinforcement passage cavity while the shell provides the outer structure and sealing surfaces. This nested configuration eliminates transport voids between separate components while maintaining the functional complexity of both elements.
Solution Approach 2:
The shell and core envelope are combined into a single integrated moulding insert assembly. The shell provides structural support and sealing, while the core envelope creates the reinforcement passage cavity. By merging these functions into one assembly, the patent reduces transport volume and simplifies handling while maintaining all necessary functions.
2Reliability
If liquid concrete is allowed to contact the reinforcement directly, then the manufacturing process is simple, but the reinforcement suffers premature degradation
Solution Approach 1:
The core envelope is extracted as a separate component that defines the reinforcement passage cavity. This cavity is completely enclosed by the core envelope walls, creating a protected channel that prevents concrete from contacting the reinforcement. The reinforcement passes through this protected cavity without direct exposure to degrading concrete environments.
Solution Approach 2:
The core envelope acts as an intermediary barrier between the liquid concrete and the reinforcement. It provides a physical separation that allows the reinforcement to be positioned and anchored while preventing direct contact with concrete that would cause premature degradation. The core envelope material and structure serve as the mediating element protecting the reinforcement.
3Strength
If the moulding insert uses a complex shape to provide sealing and mechanical strength, then the structural performance is good, but the manufacturing and assembly processes become difficult
Solution Approach 1:
The moulding insert is segmented into two main components: the shell and the core envelope. Each component can be manufactured using standard moulding processes for its specific geometric requirements. The shell is moulded with the necessary sealing surfaces and mounting features, while the core envelope is moulded as a separate cavity-forming element. This segmentation allows each part to be optimized for its specific manufacturing process.
Solution Approach 2:
The core envelope is nested inside the shell, with the core envelope's outer surface fitting within the shell's inner volume. This nested arrangement allows both complex-shaped components to be manufactured separately using conventional moulding techniques, then assembled by inserting the core envelope into the shell. The nesting configuration maintains structural integrity while enabling separate manufacturing of each component.
Data Source
AI summary
Moulding insert (8) for a mould manufacturing a concrete facing block (4) for a reinforced-ground structure (90), said reinforced-ground structure comprising a facing formed by such facing blocks and a fill in which reinforcements connected to the facing are installed, the moulding insert (8) comprising a shell (1), delimiting a general space of a connection connecting a reinforcement (3) to the facing block, a core envelope (2) obtained by moulding the shell separately, the shell having a first lateral face (15) pierced with a first orifice (11), in which a first end portion (21) of the core envelope is fitted, characterised in that the core envelope is in the general form of a truncated cone.