Lattice Support Product With Interlocking Partial Keyways
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Solution Overview
Problem
Existing pavement construction methods, whether flexible or rigid, are costly, require large material volumes, generate high CO2 emissions, and are difficult to repair, with flexible pavements prone to damage and rigid pavements susceptible to temperature-induced cracking.
Innovation Solution
A support product comprising a latticework of walls with cells and partial keyways that interlock with adjacent products, allowing for efficient construction and repair by pouring concrete into the cells, which can be connected using catches and partial keyways to restrain movement and form a stable pavement structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If flexible pavement construction methods are used, then material cost is reduced, but structural integrity and resistance to damage deteriorate
Solution Approach 1:
The pavement structure is segmented into multiple functional layers: a flexible base course layer, a rigid concrete surface course layer, and an intermediate bonding layer. This segmentation allows each layer to perform its specific function optimally while reducing overall material volume requirements compared to traditional single-structure pavements.
Solution Approach 2:
The invention uses a composite pavement structure combining flexible materials (bituminous base course) and rigid materials (concrete surface course). This composite approach provides both the cost benefits of flexible pavements and the structural integrity of rigid pavements, resolving the contradiction between material quantity and structural reliability.
2Reliability
If rigid pavement construction methods are used, then structural integrity is improved, but material cost and CO2 emissions increase
Solution Approach 1:
The pavement is divided into a thin rigid surface course layer (providing structural integrity) and a thicker flexible base course layer (providing structural support). This segmentation reduces the overall concrete volume required compared to traditional rigid pavements while maintaining necessary structural strength.
Solution Approach 2:
By combining rigid concrete surface course with flexible bituminous base course, the invention achieves the structural integrity of rigid pavements with reduced material consumption, lowering both cost and CO2 emissions compared to conventional all-concrete rigid pavements.
3Strength
If traditional flexible pavement layers are increased in depth, then structural capability is improved, but construction cost and material volume increase
Solution Approach 1:
The invention uses a composite structure where the rigid concrete surface course provides high structural capability with minimal thickness, eliminating the need for deep flexible pavement layers. The flexible base course provides necessary support while using significantly less material than traditional deep layered structures.
Solution Approach 2:
The invention changes the structural parameters by using a thin rigid layer (surface course) combined with a flexible base, rather than increasing the depth of flexible layers. This parameter change achieves superior structural capability with reduced material volume and construction cost.
4Strength
If concrete slabs are used for rigid pavement, then load distribution is improved, but temperature-induced cracking increases
Solution Approach 1:
The concrete surface course is segmented into multiple smaller slabs rather than using large continuous slabs. This segmentation reduces the span between joints, minimizing temperature-induced cracking while maintaining effective load distribution across the pavement surface.
Solution Approach 2:
The invention changes the slab size parameter by using smaller concrete slabs with increased joint frequency. This parameter change reduces thermal stress accumulation and prevents temperature-induced cracking while preserving load distribution capability through the jointed structure.
5Reliability
If flexible pavement surface course is increased in thickness, then structural integrity is improved, but resistance to water erosion and deterioration worsens
Solution Approach 1:
The invention uses a composite structure with a rigid concrete surface course that provides both structural integrity and resistance to water erosion. The concrete surface acts as an impermeable barrier preventing water infiltration, while the flexible base course provides structural support, eliminating the need for thick flexible layers that are susceptible to erosion.
Solution Approach 2:
The invention changes the material parameter of the surface course from flexible bituminous material to rigid concrete, which fundamentally alters the resistance to water erosion. This material parameter change provides superior erosion resistance while maintaining structural integrity through the concrete's inherent strength.
Data Source
AI summary
A support product configured to receive poured concrete, the support product comprising a latticework of walls and a plurality of edges, wherein the walls extend between a lower surface and an upper surface and define a plurality of cells, wherein at least one edge comprises a catch and a partial keyway, wherein the catch is configured to connect with a catch of an adjacent support product to restrain relative movement of connected support products, and wherein the partial keyway is configured to be located adjacent to a partial keyway of a connected support product, so that adjacent partial keyways define a complete keyway between connected support products.