Thermoset Polymer Utility Vault Lid Mold With Textured Surface
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Solution Overview
Problem
Existing utility vault and pit covers are heavy, difficult to remove, and lack sufficient load-bearing capacity and slip resistance, posing safety risks to workers and limiting their applicability in high-traffic areas.
Innovation Solution
A mold for manufacturing a fiber reinforced polymer material utility vault lid with a textured surface and bosses of varying heights, designed for improved slip resistance, using a low-pressure molding process with a steam pot to enhance strength and UV characteristics, and incorporating a lid ejection mechanism for easy removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heavy materials like concrete, polymer concrete, or cast iron are used for vault covers to withstand substantial loads, then load-bearing capacity is improved, but weight increases making them difficult to remove and reinstallation
Solution Approach 1:
The patent uses fiber-reinforced polymer composite materials combining glass fibers with thermoset polymer resin to create a cover that is both lightweight and strong. The composite structure provides high strength-to-weight ratio, achieving load-bearing capacity comparable to heavy materials while weighing significantly less, thus resolving the contradiction between strength and weight.
Solution Approach 2:
The patent changes the material parameters by using fiber-reinforced polymers with specific fiber orientations and resin formulations to achieve the required mechanical properties. By adjusting fiber content, fiber length, and resin type, the cover achieves adequate load-bearing capacity with reduced weight.
2Weight of moving object
If plastic lids are used to reduce weight, then ease of handling is improved, but load-bearing capacity and slip resistance deteriorate
Solution Approach 1:
The patent enhances plain plastic by incorporating fiber reinforcement (glass fibers) into the polymer matrix, creating a composite material that maintains the lightweight advantage of plastics while dramatically improving load-bearing capacity and surface friction properties.
Solution Approach 2:
The patent creates local quality variations by incorporating textured surfaces and patterns on the cover surface to improve slip resistance, while the fiber reinforcement provides localized strength enhancement in areas subjected to high loads.
3Ease of manufacture
If smooth surfaces are used on polymer covers, then manufacturing simplicity is improved, but slip resistance deteriorates when wet
Solution Approach 1:
The patent applies textured surfaces and patterns only on the top surface of the cover where slip resistance is needed, while keeping other surfaces smooth for manufacturing simplicity. This localized texturing provides improved grip when wet without complicating the overall manufacturing process.
Solution Approach 2:
The patent incorporates surface textures and patterns directly into the mold cavity, so the slip-resistant surface is formed automatically during the molding process without requiring additional post-manufacturing steps, thus maintaining manufacturing simplicity while achieving improved slip resistance.
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
The solution results in a lightweight, durable cover that withstands substantial loads, provides improved slip resistance, and is easier to install and remove, while maintaining UV stability and reduced material costs.
Implementation Method 1
using a low-pressure molding process with a steam pot to enhance strength and UV characteristics
Data Source
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AI summary
A method of manufacturing a fiber reinforced composite material lid for an utility vault including mixing an unsaturated polyester thermosetting matrix in to a resin paste, compounding the resin paste into a fiber reinforced composite material, maturing the compounded fiber reinforced composite material, cutting the matured compound into a charge pattern, molding the charge pattern in a mold cavity of a heated mold under low pressure to form the lid and cooling and machining the lid. The mold includes a cavity die and a core die having a shear angle for interfacing the core die within the cavity die and a steam pot for heating the cavity die and the core die, wherein the lid is molded between the cavity die and the core die and removed from the mold by a lid ejection mechanism.