Composite Expansion Joint for Concrete Corrosion and Wear

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Solution Overview

Problem

Existing expansion joint systems in concrete structures face issues with corrosion, poor adherence, mechanical property mismatches, and wear due to the use of metal materials, and thermosetting polymer formulations provide inadequate support and durability.

Innovation Solution

An expansion joint system comprising a substantially fully cured thermosetting polymer resin combined with a particulate aggregate material of Mohs hardness 3 to 9, and optionally reinforcing fibers, designed to match the mechanical properties of concrete structures, ensuring corrosion resistance, proper adhesion, and grindability with diamond tools.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metal materials are used for expansion joints, then structural strength and hardness are improved, but corrosion resistance deteriorates

Engineering Contradiction:

Improvestructural strengthVSAvoidcorrosion resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent employs composite materials consisting of thermosetting polymer resin combined with particulate aggregate material (such as quartz, granite, or other hard minerals) to create expansion joints that simultaneously achieve the strength of metal and the corrosion resistance of non-metallic materials. This composite approach allows the expansion joint to resist corrosion from deicing salts and moisture while maintaining adequate structural strength through the reinforcing aggregate particles.

Inventive Principle:

Principle #40Composite materials

2Strength

If metal materials are used for expansion joints, then mechanical strength is improved, but adherence to construction material deteriorates

Engineering Contradiction:

Improvemechanical strengthVSAvoidadherence

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent modifies the physical and chemical parameters of the expansion joint material by using thermosetting polymer resin that can be formulated to adhere strongly to concrete surfaces. The resin chemistry and surface properties are specifically tailored to create excellent bond strength with construction materials, eliminating the adherence problems associated with metal expansion joints.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If thermosetting polymer formulations are used for expansion joints, then corrosion resistance and adherence are improved, but mechanical strength and hardness deteriorate

Engineering Contradiction:

Improvecorrosion resistanceVSAvoidmechanical strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent reinforces the thermosetting polymer resin with particulate aggregate material having high hardness (such as quartz with Mohs hardness of 7 or granite with Mohs hardness of 6-7). This composite structure provides the necessary mechanical strength and hardness to support the surrounding concrete structure and prevent chipping, while the polymer matrix maintains corrosion resistance.

Inventive Principle:

Principle #40Composite materials

4Strength

If metal expansion joints are used, then structural support is provided, but wear resistance deteriorates due to surface topology mismatch

Engineering Contradiction:

Improvestructural supportVSAvoidwear resistance

Core Design Contradiction:

StrengthVSDuration of action of stationary object

Solution Approach 1:

The patent formulates the composite material to have surface hardness and mechanical properties that closely match those of concrete and asphalt bitumen construction materials. This parameter matching prevents the differential wear and chipping that occurs with metal expansion joints, as the composite material wears at a similar rate to the surrounding structure.

Inventive Principle:

Principle #35Parameter changes

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 provides a durable, corrosion-resistant expansion joint system that matches the mechanical properties of concrete, preventing chipping and wear, and allows for smooth grinding, ensuring long-term structural integrity and ease of maintenance.

Implementation Method 1

An expansion joint system comprising a substantially fully cured thermosetting polymer resin

Methodology Applied

Scientific EffectThermosetting polymer curing:

Implementation Method 2

a particulate aggregate material having a Mohs hardness in the range of from 3 to 9

Methodology Applied

Scientific EffectHardness:

Data Source

PatentEP2769019B1Article of manufacture made of composite material, for incorporation into a civil engineering structure

Publication Date: 2017.02.08 LEITNER

AI summary

An article (12) of manufacture is disclosed for incorporating into a civil engineering structure (3, 4), for example a concrete structure, such as a floor. The article comprises a substantially fully cured thermosetting polymer resin and a particulate aggregate material having a Mohs hardness of from 3 to 9, preferably from 5 to 8. The article optionally comprises a reinforcing fiber. The hardness of the article can be closely matched to that of the surrounding structure. The article can be ground with a diamond tool to form a smooth transition with the surrounding structure. The article is particularly suitable for incorporation into an exposed surface (7, 8) of the structure.