Composite Paving Element Adhesion via High-Pressure Compaction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing composite paving elements damage the visible side of ceramic tiles and result in high production costs due to mould unavailability during partial curing, leading to reduced production capacity.
Innovation Solution
A method involving a higher compacting pressure of over 0.8 MPa to form a concrete body adjacent to the peripheral area of a tile body, using a flowing adhesive mortar and porous mineral granules, which allows immediate mould release and enhanced adhesion, preventing adhesive layer displacement and enabling efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a low compacting pressure of maximum 0.8 MPa is used to compact concrete mortar, then the adhesive layer remains intact, but the mould must remain occupied during partial curing, reducing production capacity
Solution Approach 1:
The patent changes the pressure parameter from low (0.8 MPa) to high (above 0.8 MPa, typically 1-10 MPa). This parameter change enables the concrete mortar to achieve form-retaining properties immediately upon compaction, allowing mould release while the high pressure also ensures proper adhesion of the adhesive layer
Solution Approach 2:
The patent applies a release agent to the mould bottom and/or upright walls before placing the tile body. This preliminary action prevents the concrete mortar from adhering to the mould, enabling immediate release after high-pressure compaction without damaging the adhesive layer
2Productivity
If a high compacting pressure of more than 0.8 MPa is used to compact concrete mortar, then the mould can be released immediately, but the adhesive layer may be pressed away from between the concrete body and tile body
Solution Approach 1:
The patent introduces a release agent as an intermediary substance between the mould and the concrete mortar. This release agent mediates the high-pressure compaction process by preventing direct adhesion to the mould, allowing the pressure to be applied without damaging the adhesive layer bonding the tile and concrete bodies
Solution Approach 2:
The patent applies the adhesive layer specifically in the inner area of the tile body back side, while the peripheral area extends beyond it. This local quality distribution ensures the adhesive is positioned where bonding is needed while the peripheral area provides structural support during high-pressure compaction
3Reliability
If the adhesive layer is applied over the whole back side including peripheral area, then complete coverage is achieved, but the concrete body cannot extend to peripheral area to provide sealing edge
Solution Approach 1:
The patent applies the adhesive layer locally only in the inner area of the tile body back side, deliberately excluding the peripheral area. This local quality approach allows the concrete body to extend into the peripheral area and form a sealing edge around the adhesive layer, preventing its displacement during compaction
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 results in a durable, weather-resistant composite paving element with improved adhesion and reduced production costs, allowing for faster mould reuse and accommodating varying expansion behaviors between tile and concrete bodies.
Implementation Method 1
a back side of the tile body is provided with an adhesive layer
Implementation Method 2
the concrete mortar is compacted into the concrete body at a pressure of more than 0,8 MPa
Data Source
Figure 1~4
Figure 5~7
AI summary
The present invention relates to a method for manufacturing a composite paving element, comprising a concrete body (45) and a tile body (20) adhered thereto. The tile body is placed in a mould (10-13), wherein a visible side (21) of the tile body (20) is directed toward the mould bottom. An adhesive layer (35) is arranged on the back side (22) of the tile body. The mould is then filled with a concrete mortar (40) and the concrete mortar is compacted into the concrete body (45). The adhesive layer is provided in an inner area on the back side of the tile body and leaves clear a peripheral area which extends therearound. The concrete body extends over the peripheral area and the concrete mortar is compacted into the concrete body at a pressure of more than 8 khPa (≈80 tons/m2), particularly at a pressure of between 10 and 50 khPa (≈100-500 tons/m2), and preferably at a pressure of between about 10 and 12 khPa (≈100-120 tons/m2).