Concrete Component Accelerator Zoning for Bonding

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Solution Overview

Problem

High accelerator content in concrete for structural components leads to poor bonding between layers, reduced smoothness, and increased costs, as well as issues with reinforcement integration, necessitating a reduction in accelerator usage.

Innovation Solution

A method and system that produce structural concrete components with component-specific setting times by varying the accelerator content in different sections, allowing for optimized bonding and reduced accelerator usage, using a free-forming method like shotcrete or extrusion, where the first section sets faster with a higher accelerator content and the second section sets slower with less or no accelerator, improving bonding and smoothness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If high accelerator content is used in concrete, then application rate and layer stacking capability are improved, but bonding between layers deteriorates and reinforcement integration is compromised

Engineering Contradiction:

Improveapplication rateVSAvoidbonding between layers

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies different accelerator contents to different component sections. The first component section uses high accelerator content (0.5-2% by weight of cement) to enable rapid setting and high application rates, while the second component section uses low or no accelerator content (0-0.1% by weight of cement) to ensure proper bonding between layers and good reinforcement integration. This spatial differentiation of accelerator concentration resolves the contradiction between productivity and reliability.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The concrete component is divided into at least two distinct component sections with different accelerator contents. The first section is designed for rapid construction with high accelerator, while the second section is designed for quality bonding with low accelerator. This segmentation allows each section to optimize its accelerator content for its specific functional requirements, thereby resolving the overall contradiction.

Inventive Principle:

Principle #1Segmentation

2Duration of action of moving object

If high accelerator content is used in concrete, then setting speed is improved, but surface smoothness and bonding quality deteriorate

Engineering Contradiction:

Improvesetting timeVSAvoidsurface smoothness

Core Design Contradiction:

Duration of action of moving objectVSManufacturing precision

Solution Approach 1:

The patent implements local quality by assigning different accelerator concentrations to different sections based on their functional requirements. The first component section uses high accelerator content to achieve rapid setting, while the second component section uses low accelerator content to maintain surface smoothness and bonding quality. This localized optimization resolves the contradiction between setting speed and manufacturing precision.

Inventive Principle:

Principle #3Local quality

3Productivity

If high accelerator content is used in concrete, then construction efficiency is improved, but costs and air entrapment risk increase

Engineering Contradiction:

Improveconstruction efficiencyVSAvoidair entrapment

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent applies local quality by concentrating high accelerator content only in the first component section where rapid construction is needed, while using low accelerator content in the second component section where air entrapment risk is critical. This reduces the overall accelerator content in the concrete mix, thereby reducing air entrapment risk while maintaining construction efficiency in the critical first section.

Inventive Principle:

Principle #3Local quality

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 the risk of air entrapment, enhances the bond between concrete and reinforcement, increases productivity, and results in higher-quality structural components with improved smoothness and reduced costs by minimizing accelerator use.

Implementation Method 1

concrete which comprises an accelerator means, wherein the first component section and the second component section are produced with a free-forming method... the concrete is provided such that a first setting time of the concrete of the first component section and a second setting time of the second component section are different

Methodology Applied

Scientific EffectAccelerator means:

Data Source

PatentUS20240269886A1Method and production system for producing a concrete component, and concrete component

Publication Date: 2024.08.15 AEDITIVE GMBH

AI summary

The invention relates to a method of producing a structural concrete component (100, 200), comprising the steps of: Producing a first component section (126, 226) and a second component section (132, 232) with concrete, wherein the first component section (126, 226) and the second component section (132, 232) are produced with a free-forming method, and wherein the concrete is provided such that a first setting time of the concrete of the first component section (126, 226) and a second setting time of the second component section (132, 232) are different.