Wire-Welded Mold Core With Integrated Venting for Complex Block Shapes

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Solution Overview

Problem

Traditional mold cores for concrete cinder blocks are made from press-brake bending of metal sheets and require separate machining and assembly of ventilation valves, limiting their geometry and complicating the manufacturing process.

Innovation Solution

A mold core made from welded steel wire with integrated ventilation features, allowing for complex multi-axis curves and seamless integration of ventilation components, manufactured through welding and minimal machining.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional press-brake bending of metal sheets is used to manufacture mold cores, then the manufacturing process is relatively simple, but the geometry is limited and ventilation valves require separate machining and assembly

Engineering Contradiction:

Improvegeometry complexityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the mold core body and ventilation valve into a single integrated component made from wire mesh. The ventilation openings are formed directly in the wire mesh structure during manufacturing, eliminating the need for separate valve bodies, machining operations, and assembly steps. This integration resolves the contradiction by enabling complex geometry (ventilation features) without increasing manufacturing process complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent changes the fundamental manufacturing parameter from press-brake bending of sheets to welding of wire mesh. This parameter change enables complex multi-axis curves and integrated ventilation features to be manufactured directly in the wire mesh structure, achieving geometric versatility without requiring separate machining and assembly operations.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If separate machining and assembly of ventilation valves is performed, then the mold core structure is traditional and proven, but the manufacturing complexity increases and integration is not seamless

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidassembly complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The ventilation valve functionality is merged directly into the wire mesh mold core structure. Ventilation openings are formed as integral features of the wire mesh during manufacturing, eliminating separate valve components, machining operations, and assembly steps. This reduces both manufacturing complexity and assembly complexity simultaneously.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The wire mesh structure serves multiple functions: it forms the mold core body, provides structural integrity, and creates ventilation openings. This multi-functionality eliminates the need for separate ventilation valve components and their associated machining and assembly operations, simplifying the entire manufacturing process.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If welded steel wire is used to create mold cores, then complex geometries and integrated ventilation are achieved, but welding processes are required instead of simpler bending operations

Engineering Contradiction:

Improvegeometry complexityVSAvoidmanufacturing process simplicity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent changes the manufacturing parameter from press-brake bending to wire welding. This parameter change enables complex multi-axis curves and integrated ventilation features to be manufactured directly in the wire mesh structure, achieving geometric versatility that cannot be obtained through traditional bending operations.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The welding process merges multiple wire elements into a unified mold core structure with integrated ventilation openings. This consolidation achieves complex geometries in a single manufacturing process, eliminating the need for separate machining and assembly operations required by traditional methods.

Inventive Principle:

Principle #5Merging (Combining)

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

Enables the production of mold cores with complex geometries and efficient ventilation, reducing manufacturing complexity and improving separation of molded blocks without damage.

Implementation Method 1

The mold core wall comprises welded-together steel wire

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS20250353211A1Mold core

Publication Date: 2025.11.20 BESSER CO

AI summary

A mold core (and method for making same), for a concrete product mold comprising a mold core wall 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.