Multilayer Concrete Block Forming for Precise Thin Layer Control
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Solution Overview
Problem
Existing methods struggle to produce multiple-layer concrete blocks with a defined layer structure, particularly when producing thin layers, which is crucial for achieving desired water permeability and water storage capabilities.
Innovation Solution
A method involving a formwork-based process where the third concrete block layer is introduced first, followed by the core and facing layers, using a volumetrically-dosed cellular wheel sluice to ensure precise and uniform layer thickness, especially for the third layer, which can be water-permeable, water-impermeable, or high-strength, allowing for rapid and flexible production of concrete blocks with defined layer structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to manufacture multiple-layer concrete blocks, then the production process is simple, but the layer structure cannot be defined precisely and thin layers cannot be produced uniformly
Solution Approach 1:
The concrete block is divided into multiple distinct layers (facing layer, core layer, underside layer) with different concrete types and functions. Each layer is manufactured separately with specific properties, allowing precise control over layer thickness and composition while maintaining overall structural integrity.
Solution Approach 2:
The formwork is prepared in advance with defined geometries for each layer, and the manufacturing process follows a predetermined sequence where each layer is placed and compacted before the next layer is added. This preliminary preparation ensures precise layer thickness and uniform structure without requiring complex real-time adjustments.
2Reliability
If thin layers are produced to achieve desired water permeability, then the water permeability and water storage capabilities are improved, but the manufacturing difficulty increases
Solution Approach 1:
Different concrete types are used for different layers based on their specific functions. The facing layer uses concrete optimized for water permeability and evaporation, the core layer uses concrete for structural strength, and the underside layer uses concrete for bonding to the substrate. This localized optimization allows thin layers to achieve desired water management properties while maintaining manufacturability.
Solution Approach 2:
The manufacturing process controls parameters such as concrete composition, layer thickness, and compacting density to achieve specific water permeability and water storage capabilities. By adjusting these parameters during manufacturing, thin layers can be produced with controlled hydraulic properties without excessive manufacturing difficulty.
3Strength
If multiple layers with different concrete types are manufactured, then the water permeability and strength properties are enhanced, but the production time increases
Solution Approach 1:
The manufacturing process continues without interruption as each layer is placed and compacted directly on top of the previous layer within the same formwork. The facing layer, core layer, and underside layer are manufactured in a continuous sequence, minimizing idle time and maintaining production speed while achieving enhanced strength and water permeability properties through the multi-layer structure.
Data Source
AI summary
A method of producing concrete blocks for creating a surface covering, wherein each concrete block comprises a multiple-layer concrete block body with at least one level concrete block underside and, opposite the at least one level concrete black underside, an essentially flat concrete block upper side, wherein the multi-layer concrete block body comprises a first concrete block layer designed as a facing concrete layer and forming the concrete block upper surface, at least one second concrete block layer designed as a core concrete layer, as well as at least one third concrete block layer forming the concrete block underside. In the method at least one formwork is provided.