Welded Wire Mold Core for Vented Concrete Block Release
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Solution Overview
Problem
Traditional mold cores for concrete products, especially cinder blocks, face challenges in separation due to lack of ventilation, requiring separate machining and attachment of ventilation valves, which complicates the manufacturing process and limits the achievement of complex geometries.
Innovation Solution
A mold core design featuring a welded steel wire structure with integrated ventilation openings and vent bodies, allowing for air passage and incorporating a plug pin for easy separation, and the ability to form complex multi-axis bends, eliminating the need for separate machining of ventilation components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional press-brake bending of metal sheets is used to manufacture mold cores, then the manufacturing process is relatively simple, but the ability to achieve complex geometries is limited
Solution Approach 1:
The mold core is divided into multiple wire segments that are welded together to form the complete structure. This segmentation allows each wire to be formed into complex three-dimensional shapes independently, which are then joined to create the overall complex geometry of the mold core, resolving the contradiction between manufacturing simplicity and geometric complexity capability
Solution Approach 2:
The invention uses composite construction by welding multiple metal wire elements together to form the mold core structure. This composite approach enables the creation of complex geometries that would be difficult to achieve with single-piece forming, while maintaining manufacturing simplicity through the use of standard wire and welding processes
2Object-affected harmful factors
If ventilation valves are separately machined and attached to mold cores, then the ventilation function is achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The ventilation valve components are merged with the mold core structure through integral formation. The vent body is formed as part of the welded wire assembly, eliminating the need for separate machining and attachment operations. This merging maintains the ventilation function while significantly simplifying the manufacturing process by reducing the number of discrete components and assembly steps
Solution Approach 2:
The welded wire structure serves multiple functions simultaneously: it forms the mold core body, creates ventilation passages, and provides structural support. This multi-functionality eliminates the need for separate ventilation valve components, reducing manufacturing complexity while maintaining effective ventilation capability
3Shape
If welded steel wire structure is used for mold core, then complex geometries can be achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The mold core is segmented into multiple wire elements that can be independently formed into complex three-dimensional shapes using standard wire forming equipment. These pre-formed segments are then welded together to create the final complex geometry, breaking down the manufacturing complexity into manageable steps while achieving geometric complexity
Solution Approach 2:
The invention changes the fundamental manufacturing parameter from press-brake bending of sheets to welding of wire elements. This parameter change enables complex three-dimensional geometries to be achieved through the flexibility of wire forming and welding, while the use of standard wire and welding processes keeps the manufacturing process manageable
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 design simplifies the manufacturing process, enhances separation of concrete products by allowing airflow, and enables the creation of complex geometries that were previously unachievable, reducing manufacturing complexity and improving product integrity.
Implementation Method 1
a ventilation opening located in the mold core wall in a position to allow air to pass through the mold core wall
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A mold core (10) (and method for making same), for a concrete product mold comprising a mold core wall (16) shaped to extend from a mold surface into an interior of the mold, preventing concrete from filling an area of the mold interior when the mold core is installed on the mold surface, the mold core wall comprising welded-together steel wire (30).