Cement-Based Composite Drain Device for Corrosion Resistance
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Solution Overview
Problem
Current drain devices, particularly those made of cast iron, stainless steel, and plastic, suffer from corrosion, adhesive bond weakening, and brittleness, leading to premature failure and high maintenance and repair costs in bridge and industrial construction, with no effective solution for these issues.
Innovation Solution
A drain device made from a cement-based composite material with ultra-high-strength concrete, reinforced with fibers such as plastic, carbon, and steel, featuring a rough exterior for enhanced bonding with structural concrete and a smooth interior for efficient water drainage, significantly increasing durability and reducing maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cast iron drain devices are used, then corrosion resistance is initially good, but adhesion to concrete decreases over time and fatigue failure occurs due to stress from runoff water and de-icing agents
Solution Approach 1:
The patent applies composite materials by combining cement-based materials with fibers (steel, plastic, or glass fibers) to create a drain device that integrates the advantages of different materials: the corrosion resistance of cement and the tensile strength of fibers, eliminating the fatigue failure issues of cast iron while maintaining durability
Solution Approach 2:
The patent changes the material parameters by using ultra-high-performance concrete with compressive strength of at least 110 N/mm² and incorporating fiber reinforcement, fundamentally altering the mechanical properties to achieve both high compressive strength and high tensile strength, preventing both corrosion and fatigue failure
2Reliability
If stainless steel drain devices are used, then corrosion resistance and service life are improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent uses cement-based composite materials with fiber reinforcement as a cost-effective alternative to stainless steel, achieving comparable or superior corrosion resistance and structural performance through the synergistic combination of cement matrix and fiber reinforcement at lower material and manufacturing costs
Solution Approach 2:
The patent achieves high-performance characteristics typically associated with expensive materials like stainless steel by modifying the parameters of cement-based materials through ultra-high-performance concrete formulation and fiber reinforcement, delivering equivalent durability at reduced cost
3Ease of manufacture
If plastic drain devices are used, then manufacturing cost and weight are reduced, but service life is limited by embrittlement due to UV exposure
Solution Approach 1:
The patent replaces pure plastic materials with cement-based composite materials containing fiber reinforcement, eliminating UV-induced embrittlement while maintaining affordability and lightweight characteristics through the use of cement and synthetic fibers that are not susceptible to UV degradation
4Ease of manufacture
If conventional drain devices are replaced every 20 years, then maintenance costs are controlled, but structural damage occurs through corrosion of reinforcement and spalling of concrete
Solution Approach 1:
The patent employs cement-based composite materials with fiber reinforcement that provide superior durability and corrosion resistance, preventing the corrosion of reinforcement and spalling of concrete that occur with conventional materials, thereby extending service life well beyond 20 years and eliminating the need for frequent replacements
Solution Approach 2:
The patent incorporates fiber reinforcement within the cement-based matrix as a preventive measure to counteract future stress from runoff water and de-icing agents, providing beforehand cushioning against fatigue failure and structural damage before they can occur
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 cement-based composite drain device extends service life by approximately four times, reduces repair costs, and prevents structural damage, while being lightweight and easy to handle, with improved bonding and corrosion resistance.
Implementation Method 1
The decreasing bond between these materials and the surrounding concrete over time
Implementation Method 2
cement-based composite material with ultra-high-strength concrete
Implementation Method 3
featuring a rough exterior for enhanced bonding with structural concrete
Implementation Method 4
a smooth interior for efficient water drainage
Implementation Method 5
reinforced with fibers such as plastic, carbon, and steel
Implementation Method 6
The tensile strength is at least 5 MPa
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a drainage device, preferably a drainage tray (1) for a drain, in particular for a bridge drain or building and industrial ceiling drain, or a nozzle for a sealing drainage system, wherein the drainage device has an inlet opening (3) designed to receive a cover (5) and an outlet opening (4) connected to the inlet opening (3), wherein the drainage device consists of hardened cement-based material, and wherein the drainage device has a compressive strength of at least 110 N/mm2.