Polymer Concrete Support Blocks for Rapid Deployment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional pre-cast concrete deck blocks are heavy, prone to breakage, have limited lateral strength, and are susceptible to water and ice infiltration, making them unsuitable for rapid deployment and emergency housing applications, as well as being costly and time-consuming to produce due to their long curing time.
Innovation Solution
The development of polymer concrete support blocks with a quick set mechanism, fabricated from a mixture of monomers, aggregates, and optionally fibers, which provide improved load-bearing capabilities, are lighter, more durable, and have a faster curing time, allowing for rapid deployment and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional pre-cast concrete deck blocks are used, then they provide structural support, but they are heavy and prone to breakage
Solution Approach 1:
The patent changes the material parameters by using polymer concrete instead of conventional pre-cast concrete. This material substitution fundamentally alters the density and strength characteristics, achieving lighter weight blocks with improved structural support capability. The polymer concrete formulation allows for optimized strength-to-weight ratio that conventional concrete cannot achieve.
Solution Approach 2:
The invention employs composite materials by combining polymer resins with concrete aggregates to create polymer concrete. This composite approach integrates the high strength and ductility of polymers with the compressive strength of concrete, resulting in support blocks that are both lighter and more resistant to breakage while maintaining structural support functionality.
2Strength
If conventional pre-cast concrete deck blocks are used, then they provide load-bearing capacity, but they have long curing time
Solution Approach 1:
The patent changes the chemical parameters of the concrete material by using polymer resins as the binding agent instead of traditional cement. This parameter change fundamentally alters the curing mechanism and time requirements, enabling the support blocks to achieve sufficient load-bearing capacity in a fraction of the time required for conventional concrete curing.
Solution Approach 2:
The invention implements rapid curing by using polymer concrete technology that achieves full or near-full strength in hours rather than days or weeks. This allows the construction process to skip the extended waiting period typically required for conventional concrete to cure, enabling faster deployment and assembly as stated in the technical effects.
3Ease of manufacture
If conventional pre-cast concrete deck blocks are used, then they are cost-effective, but they are costly and time-consuming to produce
Solution Approach 1:
The patent changes the manufacturing parameters by adopting polymer concrete production methods that significantly reduce curing time from weeks to hours. Although the material cost of polymer resin may be higher than cement, the dramatic reduction in production time and the ability to produce blocks on-demand without extensive curing facilities result in overall cost-effectiveness, particularly for emergency and rapid deployment applications.
Solution Approach 2:
The invention enables preliminary production and storage of support blocks without requiring extended curing time. Blocks can be manufactured, cured rapidly, and stored for future use, providing flexibility in production scheduling and reducing the time penalty associated with on-site curing operations. This preliminary action capability makes the production process more cost-effective by decoupling manufacturing from installation timing.
4Reliability
If conventional pre-cast concrete deck blocks are used, then they provide durability, but they are susceptible to water and ice infiltration
Solution Approach 1:
The patent changes the material composition parameters by using polymer resins as the primary binding agent instead of Portland cement. This fundamental parameter change creates a material that is inherently more resistant to water absorption and freeze-thaw cycling. The polymer matrix does not absorb water like cementitious materials, eliminating the primary mechanism by which conventional concrete deteriorates in wet and frozen environments.
Solution Approach 2:
The invention uses composite materials where the polymer concrete composition combines the water resistance of polymers with the structural integrity of concrete aggregates. This composite structure creates a material that maintains durability while being immune to water and ice infiltration problems that plague conventional concrete blocks, thereby improving reliability in harsh environmental conditions.
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 polymer concrete support blocks offer enhanced load-bearing capacity, reduced weight, and increased durability, enabling faster assembly and deployment, while resisting water infiltration and freeze-thaw cycles, thus addressing the limitations of traditional concrete blocks.
Implementation Method 1
The support block can be generated by curing the mixture in a mold configured to generate the planar base plate and the one or more construction element support features
Implementation Method 2
The polymer concrete support block can have a water absorption rate of less than 1% according to ASTM D570 (2018)
Data Source
AI summary
The present disclosure relates to support blocks that can be used for decks and foundations fabricated from polymer concrete. Yet further, the present disclosure relates to deck, floor, and foundation systems comprising the disclosed support blocks. The support blocks can mate with or otherwise serve as foundation elements for use in conjunction with construction elements such as posts, joists, stringers, mounting frames, and equipment, among other things.