Plastic Composite Mold for Washed Concrete Paving
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Solution Overview
Problem
Existing water-degradable formwork molds for producing alveolate concrete paving are not suitable for creating washed or polished concrete pavings, as they degrade when exposed to water, leading to irregular cavities, reduced load-bearing capacity, and potential collapse of the paving.
Innovation Solution
A mold made from a plastic composite material, specifically a thermoplastic composite with a low thermal expansion coefficient, which is designed to maintain its shape and load-bearing capacity even when exposed to water or during the polishing process, allowing for the creation of washed or polished concrete pavings with regular cavities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a water-degradable formwork mold is used to produce alveolate concrete paving, then the mold allows water infiltration and soil ecosystem preservation, but the mold degrades when exposed to water during washing or polishing processes, leading to irregular cavities and reduced load-bearing capacity
Solution Approach 1:
The patent changes the material parameter of the mold from water-degradable to water-resistant plastic composite material, enabling the mold to withstand water exposure during washing and polishing processes without degrading, thus maintaining cavity regularity and load-bearing capacity
Solution Approach 2:
The patent uses a plastic composite material for the mold that combines durability with the required functional properties, creating a composite structure that resists water degradation while maintaining the necessary formwork characteristics for producing permeable concrete paving
2Manufacturing precision
If a heavy concrete polishing machine is applied before the concrete sets, then the concrete surface can be polished to a smooth finish, but the water-degradable mold cannot retain its shape under the machine's weight, causing paving collapse
Solution Approach 1:
The patent changes the mechanical strength parameter of the mold material to withstand heavy loads from polishing machines, transforming the mold from a fragile water-degradable material to a robust plastic composite that can support the weight of heavy equipment during the polishing process
Solution Approach 2:
The patent enables the polishing operation to be performed before the concrete fully sets by providing a mold strong enough to support the polishing machine's weight during this early stage, allowing the smoothing action to occur while the mold maintains its shape under load
3Ease of manufacture
If the mold degrades during concrete curing and treatment, then the paving can be produced with initial formwork functionality, but the cavity edges become irregular and cannot withstand traffic impact, reducing paving lifetime
Solution Approach 1:
The patent changes the durability parameter of the mold material, transforming it from a temporary water-degradable formwork to a long-lasting plastic composite mold that maintains its structural integrity throughout the entire paving lifecycle, including curing, treatment, and traffic loading phases
Solution Approach 2:
The patent provides beforehand cushioning against traffic impact by using a robust mold that creates regularly shaped cavities with reinforced edges, preparing the paving structure to withstand future traffic loads without degradation-induced irregularities
4Reliability
If the mold degrades during concrete curing, then the initial formwork function is achieved, but the paving surface becomes uneven and uncomfortable for driving
Solution Approach 1:
The patent changes the dimensional stability parameter of the mold material, ensuring the mold maintains its precise geometric shape during concrete curing and treatment processes, thereby producing a level and smooth paving surface suitable for comfortable driving
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
The plastic composite mold enables the creation of high-quality, level, and smooth permeable concrete pavings with regular cavities, improved load-bearing capacity, and extended lifetime, while allowing for the application of concrete polishing machines before the concrete sets.
Implementation Method 1
The mold is made from a plastic composite material... The application of water in the process of washing the concrete or the use of a concrete with a high water/concrete ratio and/or with additives or films to retain more water in the concrete to allow the polishing process, does less or even not degrade the former.
Implementation Method 2
the plastic composite material is a thermoplastic composite material, preferably with a thermal expansion coefficient below 0.20 mm/m°C and more preferably below 0.17 mm/m°C
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3c
AI summary
The invention provides a mold (101) for shaping cast-in-place concrete paving (702) that comprises a void former (102) and a base plane (105). The void former comprises a void former wall (103) and a void former cover (104). The base plane comprises a void former through hole. The void former cover lies transverse to the void former wall and the void former wall lies transverse to the base plane. The void former wall connects the void former cover to the base plane, respectively along a void former cover edge (106) delimiting the void former cover and a void former through hole edge (107) delimiting the void former through hole. The void former protrudes from the base plane, forming a hollow peak determining a void former volume. The mold is made from a plastic composite material. The invention further provides a paving comprising a mold, a method of using a mold and a method of making a mold.