Elastic Sealing Member for Stone-Coated Concrete Elements
Solution Overview
Problem
Existing methods for producing construction elements with natural stone coatings face challenges such as leakage of wet concrete, especially when using self-compacting concrete, and are limited to producing elements with only one side coated, requiring two elements to be placed back-to-back for a two-sided stone wall.
Innovation Solution
A method involving a mould with two concrete sublayers, where self-compacting concrete forms the upper layer and basic concrete the lower layer, with an elastic member protruded into slits between stone coatings on reinforcement means to prevent leakage and allow for two-sided stone wall production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If self-compacting concrete is used to produce construction elements with natural stone coatings, then productivity and ease of manufacture are improved, but concrete leakage through slits between stones occurs
Solution Approach 1:
A sealing element made of elastic material is introduced as an intermediary component between the concrete and the stone coating elements. This sealing element fits into recesses in the reinforcement structure and protrudes into the slits between stones, preventing concrete leakage while allowing the self-compacting concrete to be used for high productivity.
Solution Approach 2:
The sealing element is made of elastic material that can deform to fit the contours of the stone arrangement. This flexible sealing component adapts to the irregular spaces between natural stones, effectively blocking concrete leakage paths while maintaining the overall structure integrity.
2Device complexity
If methods producing single-sided stone coating are used, then manufacturing complexity is reduced, but two elements must be placed back-to-back to create two-sided stone walls
Solution Approach 1:
The mould and reinforcement structure are designed with symmetry and multi-functionality, allowing the same single mould to produce elements with stone coating on multiple sides. The reinforcement structure includes recesses for sealing elements on opposite sides, enabling the production of two-sided stone wall elements in a single manufacturing process, thereby improving assembly efficiency.
3Ease of manufacture
If natural stones are loaded directly on mould bottom with sand filling slits, then ease of manufacture is improved, but concrete leakage cannot be prevented
Solution Approach 1:
Instead of using sand as a simple filler, a specialized sealing element made of elastic material is introduced as an intermediary component. This sealing element is placed in recesses of the reinforcement structure and protrudes into the stone slits, actively preventing concrete leakage while maintaining the simplicity of direct stone loading on the mould bottom.
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 effectively prevents concrete leakage and allows for the production of construction elements with both sides coated in natural stones, enabling efficient assembly and reducing site clutter and construction time.
Implementation Method 1
an elastic member arranged on the layered coating elements and protruded into slits between the coating elements
Data Source
Figure 1A~3
Figure 4~6
Figure 7~8
AI summary
The present invention relates to methods for producing construction elements which outermost surface is coated with coating elements (106) such as natural stones or the like. For forming the outermost surface, the method comprises mounting an arrangement (105) comprising the coating elements (106) layered on reinforcement means (107) and an elastic member (108) arranged on the layered coating elements and protruded into slits between the coating elements on a concrete layer (101) and removing the elastic member. The invention relates also to the arrangement (105) for producing the construction elements according to the method, and a lifting means (110) for use in the method.