Composite Reinforcement Cage for Tunnel Segments
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Solution Overview
Problem
Current tunnel segment construction using metal-reinforced concrete faces challenges such as difficulty in demolition, high costs for separating metal components, and corrosion issues due to chemical reactivity, especially in aggressive environments, while fiberglass reinforcements are costly and have adhesion problems with concrete.
Innovation Solution
A method for producing tunnel segments using unidirectional composite material with a modular reinforcement cage design, comprising flat elements and seaming techniques, where fiberglass or similar materials are impregnated with resin and pretensioned around fixed pins to create a strong, corrosion-resistant structural reinforcement without metal components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal reinforcement is used in concrete segments, then structural strength is achieved, but demolition becomes difficult and costly due to inability to cut steel
Solution Approach 1:
The patent changes the material parameter of the reinforcement from metal to composite material. This substitution maintains the required structural strength while fundamentally altering the demolition characteristics, allowing segments to be cut and demolished without the difficulties associated with metal reinforcement.
Solution Approach 2:
The patent employs composite materials as the reinforcement medium instead of traditional metal. This composite reinforcement provides equivalent or superior structural strength while enabling easier demolition through cutting operations, as composite materials can be more readily separated and processed than metal-reinforced concrete.
2Strength
If metal reinforcement is used in segments, then structural integrity is provided, but separation of metal components after demolition incurs high costs
Solution Approach 1:
The patent changes the material composition parameter from metal-based to composite-based reinforcement. This substitution maintains structural integrity while eliminating the need for expensive metal separation processes, as composite materials can be more easily processed and disposed of or reused without specialized separation equipment.
3Strength
If metal reinforcement is used in segments, then load-bearing capacity is achieved, but corrosion resistance deteriorates in aggressive chemical environments
Solution Approach 1:
The patent changes the chemical composition parameter of the reinforcement material from metal to composite. This substitution maintains load-bearing capacity while dramatically improving corrosion resistance, as composite materials do not undergo electrochemical corrosion like metal in aggressive environments such as sewer pipes or coastal areas.
Solution Approach 2:
The patent uses composite materials as reinforcement, which inherently provide superior corrosion resistance compared to metal. The composite structure resists chemical attack from aggressive environments, eliminating the need for additional waterproofing layers and their associated maintenance requirements.
4Reliability
If fiberglass reinforcement is used instead of metal, then corrosion resistance is improved, but adhesion to concrete deteriorates
Solution Approach 1:
The patent introduces an intermediary substance (adhesive or surface treatment) between the fiberglass reinforcement and concrete. This intermediary layer compensates for the poor natural adhesion of composite materials to concrete, ensuring adequate bond strength while maintaining the corrosion resistance benefits of fiberglass reinforcement.
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
This approach reduces production costs, enhances structural performance, and prevents corrosion by ensuring stable adhesion of composite materials to concrete, allowing for efficient and cost-effective construction of tunnel segments with improved durability and reduced maintenance.
Implementation Method 1
fiberglass or similar materials are impregnated with resin
Implementation Method 2
pretensioned around fixed pins to create a strong, corrosion-resistant structural reinforcement
Data Source
Figure 1~2(b)
Figure 3~5
Figure 6~7
AI summary
Method of producing cement segments (100) for tunnels, reinforced with composite material, and product thus obtained, consisting of the steps of: (A) preparing the unidirectional composite yarn (8), and transferring it to a nozzle (6);(B) making the primary reinforcement (1), by the sub-steps of: (B.1) arranging fixed pins (5) on a translating board (4) which moves through a moving mechanism; said fixed pins (5) forming a closed polygonal line (9) corresponding to the shape of the primary reinforcement (1); (B.2) pre-tensioning, in which the unidirectional composite yarn (8) is pretensioned around the closed polygonal line (9); (C) making the secondary reinforcement (2), by the sub-steps of:(C.1) arranging a plurality of fixed pins (5) on said board (4); (C.2) pre-tensioning;(D) assembling the primary reinforcement (1) into the housings (2.1) arranged on the secondary reinforcement (2), forming the structural cage (10) of the segment (100); (E) strengthening, in which a seam is made to stably connect the primary reinforcement (1) to the secondary reinforcement (2); (F) casting, in which the concrete is cast forming the cement segment (100) for tunnels.