Polymer Concrete Molded Elements with Photoluminescent Base Layer
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Solution Overview
Problem
Existing methods for producing molded elements with photoluminescent properties are not cost-effective and do not provide sufficient chemical and mechanical resistance, limiting their durability and surface quality.
Innovation Solution
The method involves forming molded elements from polymer concrete with photoluminescent particles exclusively in the base layer, surrounded by a surface layer with high mechanical and chemical resistance, allowing for efficient use of photoluminescent particles and optional additional particles for optical effects, and assembling these elements into composite panels with variable patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If photoluminescent particles are admixed in the entire shaped element, then photoluminescent properties are achieved, but production costs increase and particle usage is excessive
Solution Approach 1:
The patent applies local quality by concentrating photoluminescent particles exclusively in the base layer rather than distributing them throughout the entire shaped element. The base layer has thickness d3 and contains the photoluminescent particles, while the surface layer has thickness d2 and remains free of these particles. This localized placement ensures photoluminescent properties are achieved in the visible area while significantly reducing the total amount of expensive photoluminescent particles required, thereby lowering production costs.
2Reliability
If a surface layer with high mechanical and chemical resistance is applied, then durability and surface quality are improved, but production complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the shaped element into two distinct functional layers: a surface layer (thickness d2) providing high mechanical and chemical resistance, and a base layer (thickness d3) containing photoluminescent particles. This segmentation allows each layer to be optimized for its specific function and applied in separate sequential steps, making the production process manageable and systematic rather than overly complex.
Solution Approach 2:
The patent applies preliminary action by first applying the surface layer with high mechanical and chemical resistance before applying the base layer containing photoluminescent particles. This sequential approach ensures that the protective surface layer is established first, creating a stable foundation, and then the photoluminescent base layer is applied on top. This preliminary arrangement simplifies the overall production process by breaking it into logical, sequential steps.
3Ease of manufacture
If photoluminescent particles are placed only in visible areas, then production costs are reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies local quality by confining photoluminescent particles to the base layer which has a defined thickness d3, ensuring they are positioned only in visible areas where they serve their photoluminescent function. This localized placement in the base layer, beneath the surface layer, automatically achieves cost reduction while the layered structure provides a natural framework that guides particle placement without requiring excessive manufacturing precision.
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 approach reduces production costs, enhances the durability and surface quality of molded elements with photoluminescent properties, and allows for versatile and cost-effective production of elements with improved chemical and mechanical resistance.
Implementation Method 1
Methode zur Herstellung von Formkörpern mit photolumineszierenden Partikeln... Formkörper (1), die aus Polymerbeton gebildet werden, in deren Basis-Schicht (3), welche von einer Oberflächen-Schicht (2) bedeckt und geschützt ist, photolumineszierende Partikel... eingeführt werden
Data Source
Figure 1~2
AI summary
The invention relates to a method for producing molded elements (1) comprising photoluminescent and/or night luminous particles (6). According to the invention, the molded elements (1) are formed of polymer concrete, in the base layer (3) of which photoluminescent and/or night luminous particles (6) and/or further particles (7) are introduced, the base layer being covered and protected by a surface layer (2). The invention further relates to a molded element (1) comprising photoluminescent and/or night luminous particles (6) and an assembly comprising a plurality of molded elements (1).