Canal Component Coating with Plasticised Plastics Material
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Solution Overview
Problem
Existing methods for manufacturing canal components with plastics material cladding are inefficient, requiring high amounts of plastics, complex tools, and result in increased cycle times, while failing to effectively protect against both liquid and gas aggression in wastewater systems, leading to premature wear and damage.
Innovation Solution
A method involving coating a concrete base body with plasticised plastics material in the regions of internal walls and connection portions, which cures to form a continuous, seamless layer, providing effective sealing against liquids and gases, and using a rotating nozzle for uniform application, along with a separate work step for plastics material curing, allowing for flexible and cost-effective manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a shaft base is produced as a self-supporting structure from plastics material in a thermoforming process, then the shaft base provides structural stability, but a relatively high amount of plastics material is required and the process requires relatively complex tools
Solution Approach 1:
The invention divides the plastics material application into two separate components: a reusable moulding body that provides the conduit structure and a separate plastics material layer that is applied to the moulding body. This segmentation allows the structural function to be provided by the moulding body while the protective cladding function is provided by the applied plastics layer, reducing the total amount of plastics material required compared to producing a complete self-supporting shaft base from plastics.
Solution Approach 2:
The invention introduces a reusable moulding body as an intermediary element that serves as a temporary support structure during manufacturing. This moulding body allows the plastics material layer to be applied in a controlled manner and then removed, eliminating the need for complex thermoforming tools and reducing plastics material consumption while maintaining structural stability during the manufacturing process.
2Manufacturing precision
If the plastics material layer is applied to the moulding body directly in the mould, then the cladding is applied at the manufacturing site, but the mould is inaccessible during the application and curing of the plastics material, resulting in increased cycle time
Solution Approach 1:
The invention separates the plastics material application process from the moulding process by applying the plastics layer to the removed moulding body in a separate work area. This allows the mould to be immediately reused for producing the next concrete base body, eliminating idle time and increasing productivity while maintaining precise cladding application through controlled environment conditions.
Solution Approach 2:
The invention performs the plastics material application and curing as a preliminary action after moulding but before final assembly. By applying the plastics layer to the removed moulding body in a separate work area with controlled conditions, the process ensures precise application while allowing parallel production of multiple components, thereby reducing overall cycle time.
3Reliability
If different spatial or climatic conditions are required for applying and curing the plastics material and for pouring and curing the concrete, then the separate work area allows optimal conditions for each process, but the process sequence becomes less flexible
Solution Approach 1:
The invention segments the manufacturing process into distinct spatial zones: a moulding area for concrete base body production and a separate work area for plastics material application and curing. This spatial segmentation allows each process to occur under its optimal conditions independently, while the modular nature of the separated processes maintains flexibility in sequencing and adaptation to different production requirements.
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 achieves reliable sealing of canal components, preventing liquid and gas contact with concrete, reducing wear, and enabling efficient, cost-effective manufacturing with improved flexibility and surface quality of the plastics material layer.
Implementation Method 1
coating the base body with a plasticised plastics material in the region of the connection portion and in the region of an internal wall of the base body facing the canal inner space, and curing the plastics material
Data Source
AI summary
The present invention relates to a method for manufacturing a canal component which comprises a connection portion 104, 106 designed to come into contact with a component 100, in particular an adjacent canal component, which is to be connected to the canal component 100, the method comprising the following steps: providing a concrete base body, coating the base body with a plasticized plastics material 110 in the region of the connection portion 104, 106 and in the region of an internal wall (108) of the base body facing the canal inner space 106, and curing the plastics material (110).