Recycled Rubber Expansion Joint Insert with Flow-Controlled Extrusion
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Solution Overview
Problem
Traditional concrete expansion joint inserts made from materials like wood, paper, and asphalt are not durable and do not effectively accommodate the expansion and contraction of concrete due to weather changes.
Innovation Solution
The development of a method and device for extruding recycled rubber material into concrete expansion joint inserts, where the material flow is controlled to achieve an equal flow rate through the middle and outside edges of the insert, ensuring consistent dimensions and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional materials (wood, paper, asphalt) are used for expansion joint inserts, then the initial cost is low and ease of manufacture is good, but durability and ability to accommodate concrete expansion/contraction deteriorate
Solution Approach 1:
The patent changes the material parameter from traditional wood/paper/asphalt to recycled rubber, fundamentally altering the durability and elastic properties of the expansion joint insert while maintaining manufacturability through extrusion processes
2Reliability
If recycled rubber material is used for expansion joint inserts, then durability and ability to accommodate concrete expansion/contraction are improved, but manufacturing precision and dimensional consistency deteriorate due to material flow variability
Solution Approach 1:
The patent applies local quality by creating specific flow control features (ridges, grooves, or variations in die opening) at particular locations within the extrusion die to locally adjust material flow and achieve uniform dimensional characteristics throughout the recycled rubber insert
Solution Approach 2:
The patent modifies the extrusion process parameters by controlling material flow rate, temperature, and pressure to ensure consistent dimensional output from the recycled rubber material while maintaining its elastic properties
3Device complexity
If material flow rate varies across the flow path, then manufacturing complexity is reduced, but manufacturing precision and dimensional consistency deteriorate
Solution Approach 1:
The patent introduces local flow control features (such as ridges, grooves, or variations in die opening) at specific positions within the extrusion die to locally adjust material flow distribution and achieve uniform dimensional characteristics
Solution Approach 2:
The patent implements feedback control in the extrusion process by monitoring and adjusting material flow rate, temperature, and pressure parameters to maintain consistent dimensional output from the recycled rubber material
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 solution provides durable and dimensionally consistent concrete expansion joint inserts made from recycled rubber, effectively accommodating the expansion and contraction of concrete while maintaining a visually appealing appearance.
Implementation Method 1
an extruder a device that receives material from the extruder. The device includes a flow path through the device
Data Source
AI summary
A concrete expansion joint insert includes a body having two ends, two longitudinal edges between the ends and two side surfaces between the longitudinal edges. The body has a length, a width and a thickness. The length is greater than the width and the width is greater than the thickness. The width and thickness correspond to dimensions of the ends of the body. The length and the thickness correspond to dimensions of the longitudinal edges. The length and the width correspond to dimensions of the side surfaces. At least a portion of the body has a first surface characteristic and at least one of the longitudinal edges has a second surface characteristic that is different than the first surface characterization. The second surface characteristic comprises at least one of a color, a texture and a profile.