Concrete Component Rolling for Fiber Orientation and Strength
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Solution Overview
Problem
Existing methods for producing prefabricated concrete components with enhanced bending tensile strengths and variability in component geometry are limited in achieving satisfactory anisotropic properties, particularly in terms of fiber orientation and dimensionability.
Innovation Solution
A method involving longitudinal rolling of mineral-bound mass with fibers between counter-rotating rollers to achieve thickness reduction and controlled fiber orientation, allowing for adjustable deformation and subsequent processing to achieve desired component geometries, including the use of multiple rolling passes and joining techniques to maintain or enhance anisotropy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional pouring or injection methods are used to produce concrete components, then the manufacturing process is simple and easy to operate, but the achievable bending tensile strength is insufficient and fiber orientation cannot be controlled
Solution Approach 1:
The patent changes the physical state parameters of the concrete mass by controlling the water-cement ratio to be less than 0.6, creating a plastic, rollable state. This parameter change enables the mass to be deformed through rolling while maintaining coherence, allowing fibers to align in the rolling direction and achieve high bending tensile strengths without complex reinforcement structures
Solution Approach 2:
The patent uses counter-rotating rollers to apply curved deformation to the concrete mass, forcing it through a narrowing gap between the rollers. This curved forming action creates longitudinal stretching and aligns fibers in the rolling direction, transforming the mass from an isotropic to an anisotropic structure with enhanced tensile properties
2Adaptability or versatility
If fibers are added to improve tensile strength, then the concrete exhibits better tensile properties, but the variability and adaptability of component geometry is limited
Solution Approach 1:
The patent employs dynamically adjustable roller gaps that can be varied during the rolling process. By changing the gap size between rollers, the degree of deformation and fiber alignment can be controlled, enabling production of components with different geometries and anisotropic properties while maintaining precise fiber orientation control through the rolling direction
3Strength
If the water-cement ratio is reduced to improve green strength, then the mass can support its own weight, but the workability and formability of the mass decreases
Solution Approach 1:
The patent identifies a critical parameter window where the water-cement ratio is less than 0.6, creating a plastic state that simultaneously provides sufficient green strength to support the mass's own weight during rolling while maintaining adequate formability. This parameter change enables the mass to be deformed through rollers without disintegrating, achieving both strength and workability requirements
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 method significantly increases bending tensile strengths up to over 100 MPa by aligning fibers in preferred directions, enabling the production of components with tailored anisotropic properties suitable for specific load orientations, and allows for the production of large-format components with improved structural integrity.
Implementation Method 1
The mineral-bound mass with the fibers it contains thus forms the rolled stock in metallurgical terms, which undergoes longitudinal stretching (increase in length) as a result of longitudinal rolling. This plastic forming results in a change in the (average) fiber orientation of the fibers contained in the rolled stock
Implementation Method 2
In the case of mineral masses, a rheology comparable to that of a Bingham fluid also applies. In this respect, it is also preferred that the mass to be rolled has a Bingham viscosity η Bi (in bar xs) of at least 0.01, preferably at least 0.02, in particular at least 0.03 and/or not greater than 1.8
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
Method for manufacturing components of a given component geometry, in particular for concrete structures, in which a fiber-containing, still deformable, mineral-bound, in particular cement-bound mass is produced, this mass is subjected to one or more forming processes and finally solidified in a structure that allows the preservation of the component geometry, wherein at least one forming process of the mass lies in a longitudinal stretching of the mass caused by carrying it out between two counter-rotating rollers that reduce the thickness dimension of the mass.