Tunnel Caisson Closure Cheek with Localized Surface Features
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Solution Overview
Problem
Existing tunnel box closure cheeks for roller shutters or blinds in masonry structures do not effectively facilitate thermal insulation due to gaps between insulation panels and structural components, allowing air movement that compromises insulation efficiency.
Innovation Solution
A closure cheek with a smooth, vertical surface on the internal face and protruding asperities on the external face, allowing for direct, gap-free application of insulation panels and enhanced sealing with elastomeric materials for improved air and water tightness, including features like a gutter for rail engagement and hollow cylindrical housing for electric cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If protruding asperities are provided on the entire outer face of the cheek for binder connection, then connection strength with masonry is improved, but thermal insulation performance deteriorates due to air gaps between insulation panels and the cheek surface
Solution Approach 1:
The cheek surface is divided into two distinct zones: the external face retains protruding asperities for binder connection with masonry, while the internal face (facing the building interior) is made smooth and flat to enable direct contact with thermal insulation panels. This local differentiation allows each surface to optimize its function - the external surface provides mechanical anchoring while the internal surface eliminates air gaps for improved thermal insulation.
2Loss of energy
If a smooth surface is provided on the internal face of the cheek for insulation contact, then thermal insulation performance is improved, but connection strength with binder deteriorates
Solution Approach 1:
The cheek surface is divided into two distinct zones: the external face retains protruding asperities for binder connection with masonry, while the internal face (facing the building interior) is made smooth and flat to enable direct contact with thermal insulation panels. This local differentiation allows each surface to optimize its function - the external surface provides mechanical anchoring while the internal surface eliminates air gaps for improved thermal insulation.
3Ease of operation
If the cheek structure is modified to include a smooth internal face, then manufacturing complexity increases, but installation ease improves
Solution Approach 1:
The cheek is segmented into distinct functional zones during manufacturing - the external face with asperities and the internal smooth face. This segmentation is integrated into the single cheek component, allowing it to be produced as one piece with differentiated surfaces. The segmentation enables the cheek to fulfill multiple functions (binder anchoring and insulation contact) without requiring separate components, thus simplifying installation while maintaining manageable manufacturing complexity.
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 significantly enhances thermal insulation by eliminating air gaps between insulation and structural components, ensuring better air and water tightness, and facilitating easier installation with improved sealing capabilities.
Implementation Method 1
at least the central part of the outer face of the flange has protruding asperities to promote the connection with a binder and the structural work
Implementation Method 2
The absence of protruding asperities on the part of the cheek protruding with respect to the structural work allows good positioning of the insulating lining in line with this protruding end of the tunnel box
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The plate (4) has an external face (8) including a vertical flat smooth surface (8a) in a portion when the plate is positioned, where the portion is protruded toward interior of a building with respect to a carcass. A central portion (8b) of the external face includes protruding asperities e.g. longitudinal ribs (8b.1) and vertical ribs (8b.2) for promoting connection with a binder and the carcass. A lower face (9) comprises a horizontal flat smooth surface corresponding to a protruding portion on the carcass of the lower face, and is in contact with top of masonry and/or thermal insulation.