Reinforced Soil Facing Element Anchors with Flexible Void Formers
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Solution Overview
Problem
Existing methods for manufacturing anchoring elements in reinforced soil structures are complex, costly, and prone to surface defects, with reusable void formers being inefficient and metallic inserts causing corrosion issues.
Innovation Solution
A method using flexible inserts made of materials like polyurethane to form channels around anchoring cores, allowing easy removal and reuse, with features like connector parts and support structures to maintain shape during casting and extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hollow plastic sleeves are used as void formers, then the anchoring elements can be formed, but the manufacturing cost increases and the sleeves cannot be retrieved for reuse
Solution Approach 1:
The patent applies the discarding and recovering principle by designing a reusable void former system. The void former is removed from the mold after casting, and the mold is reused for subsequent productions. This eliminates the need for disposable hollow plastic sleeves, reducing manufacturing costs while maintaining reliable anchoring element formation.
2Reliability
If removable inserts are used to form channels around steel anchors, then the anchoring elements can be formed, but corrosion issues arise from metallic parts
Solution Approach 1:
The patent applies the disposable principle by using a flexible material void former that is discarded after a single use. This flexible material does not corrode like metallic inserts, eliminating corrosion issues while still forming the necessary channels around anchoring cores.
3Shape
If two halves of rigid void former are joined together, then the channel cross-section can be enlarged, but split lines or surface defects are created at the junction
Solution Approach 1:
The patent applies the flexible shell principle by using a flexible material void former instead of rigid halves joined together. The flexible material conforms to the mold geometry, creating smooth channel cross-sections without split lines or surface defects at junctions, while still achieving the necessary cross-sectional enlargement.
4Reliability
If complex casting assemblies are used, then the anchoring elements can be formed, but the manufacturing process becomes expensive and time-consuming
Solution Approach 1:
The patent applies the segmentation principle by separating the void former from the mold, allowing independent removal and reuse. This simplifies the casting assembly into manageable components, reducing manufacturing complexity and time while maintaining reliable anchoring element formation.
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
Facilitates efficient, cost-effective production of robust anchoring elements with reduced surface defects, ensuring durable connections between reinforcements and facing elements.
Implementation Method 1
Removing the void former comprises pulling the at least one insert away from a rear surface of the facing element, the flexible material of the at least one insert being deformed around the anchoring core while it is pulled
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
A void former is arranged in a mold (30). The void former includes an insert (1) made of flexible material that forms a loop around a core region (15) within the mold. Casting material is added in a fluid state into the mold so as to fill a predefined volume for the facing element, including the core region. After hardening of the casting material, the facing element (10) is removed from the mold, and the void former is removed from the facing element. The facing element comprises an anchoring core formed by the hardened casting material in the core region (15). Removing the void former comprises pulling the insert (1) away from a rear surface of the facing element (10). The flexible material of the at least one insert is deformed around the anchoring core (15) while it is pulled.