3D-Printed Sealing Elements for Custom Waterproof Penetrations
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Solution Overview
Problem
Existing sealing elements for anchor penetrations and injection holes in tunneling and waterproofing applications often require standardized designs, leading to insufficient or insecure waterproofing capabilities, especially when dealing with large anchors or non-standard membrane materials.
Innovation Solution
Customized sealing elements are produced using additive manufacturing technology with a polymeric composition comprising at least 35% polymer and 25% inorganic filler, eliminating weld lines and adhesively bonded sections to ensure high-quality, cost-effective production of complex shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If standardized sealing element designs are used, then manufacturing cost and production efficiency are improved, but waterproofing performance becomes insufficient for special applications
Solution Approach 1:
The patent applies parameter changes by transitioning from standardized sealing element designs to customized designs with varying geometric parameters (dimensions, shapes, configurations) tailored to specific application requirements. This allows the sealing elements to adapt to different anchor sizes, penetration types, and waterproofing needs while maintaining production efficiency through additive manufacturing processes.
2Reliability
If customized sealing element designs are produced using traditional methods, then waterproofing performance is improved, but material failure risk increases due to weld lines and adhesively bonded sections
Solution Approach 1:
The patent replaces traditional mechanical joining methods (welding and adhesive bonding) with additive manufacturing technology. This substitution eliminates weld lines and adhesively bonded sections that create weak points and potential failure sites, resulting in monolithic sealing elements with uniform material properties and reduced material failure risk while maintaining customized designs for optimal waterproofing performance.
3Adaptability or versatility
If traditional manufacturing methods are used for customized sealing elements, then design flexibility is improved, but production cost increases significantly
Solution Approach 1:
The patent changes the manufacturing process parameters by adopting additive manufacturing technology, which allows for easy modification of design parameters (dimensions, shapes, configurations) without requiring new tooling or molds. This enables cost-effective production of customized sealing elements, as the digital model can be updated and printed on-demand, eliminating the high costs associated with traditional custom manufacturing methods.
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 method allows for the production of individualized sealing elements with lower material failure risks, ensuring consistent waterproofing quality and cost efficiency, independent of lot size.
Implementation Method 1
producing a sealing element (1) by additive manufacturing
Data Source
Figure 1
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AI summary
The invention relates to a method for producing a sealing element, the method comprising steps of: i) Providing a digital model of a sealing element (1) and ii) Based on the digital model, producing a sealing element (1) by additive manufacturing, wherein the sealing element (1) comprises a baseplate (2) and a tubular extension (3) projecting outwardly from the baseplate (2) and wherein the baseplate (2) and/or the tubular extension (3) is composed of a polymeric composition comprising: a) At least 35 wt.-%, preferably at least 45 wt.-%, of at least one polymer P selected from PVC, polyolefins, halogenated polyolefin, rubbers, and ketone ethyl esters and b) At least 25 wt.-%, preferable at least 30 wt.-%, of at least one inorganic filler F, all proportions being based on the total weight of the polymeric composition.