Integrated Seal Disc for Watertight Tunnel Lining Fixing
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Solution Overview
Problem
Existing tunnel lining systems face challenges with water leakage through bolt perforations, require numerous components leading to high installation time and risk of corrosion, and are inefficient in maintaining sealing over time due to compressible insulation materials like PE foam.
Innovation Solution
A disk with integrated seals on both sides, one facing the bolt and the other the lining, providing a watertight transition and using a spacer for compressible materials, manufactured through injection molding to reduce weight and installation complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate sealing components (plates, discs, rubber seals) are used with rock anchor bolts, then sealing against water intrusion is achieved, but the number of components increases leading to complex installation and higher corrosion risk
Solution Approach 1:
The patent combines multiple separate sealing components (backing plate, rubber seal, front washer) into a single integrated disc component. The disc includes an integrated sealing element that performs the sealing function previously requiring multiple separate parts, thereby reducing component count while maintaining sealing effectiveness against water intrusion through bolt perforations.
Solution Approach 2:
The integrated disc serves multiple functions simultaneously: it acts as a backing plate for structural support, incorporates a sealing element to prevent water leakage, and provides a mounting surface for the lining. This multi-functional design eliminates the need for separate components and simplifies the overall assembly.
2Reliability
If multiple separate components are used for lining fixation, then sealing is achieved, but installation time increases due to assembly complexity
Solution Approach 1:
By integrating the sealing element directly into the disc structure, the patent enables a single-component installation process. The disc is installed in one piece with the sealing element already positioned, eliminating the need for separate assembly steps required when using multiple components, thereby reducing installation time while maintaining sealing durability.
Solution Approach 2:
The sealing element is pre-integrated into the disc during manufacturing, with the sealing surface and sealing element positioned in their final configurations before installation. This preliminary preparation eliminates the need for on-site assembly and adjustment of separate sealing components, significantly reducing installation time.
3Strength
If steel discs with anti-corrosion coating are used, then structural strength is maintained, but handling and installation become more difficult due to weight
Solution Approach 1:
The patent employs composite material construction for the disc, combining materials that provide both structural strength and reduced weight. The integrated design allows optimization of material distribution, using stronger materials only where structurally necessary while employing lighter materials in non-critical areas, achieving strength-to-weight ratio improvement.
4Temperature
If compressible insulation materials like PE foam are used, then insulation performance is improved, but sealing reliability decreases over time due to material compression
Solution Approach 1:
The patent applies different material properties to different regions of the disc structure. The sealing surface is designed with specific local characteristics that accommodate the compressible insulation material while maintaining sealing pressure. The integrated sealing element is positioned and configured to work specifically with compressible materials, providing localized sealing action that compensates for material compression over time.
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 integrated seal disk ensures robust, long-lasting sealing, reduces installation time and weight, and minimizes material handling risks, enhancing safety and efficiency while maintaining insulation integrity.
Implementation Method 1
the seal only protrude on one side of the disk intended to face towards the lining... a seal for sealing the bolt is either preinstalled onto the disk or retrofitted outside of the disk
Data Source
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AI summary
A disk (1) for sealed attachment and support of a lining or insuation plate or mat (11) to a supporting surface, such as a wall and/or ceiling in a tunnel (10), the lining (11) being intended to be fixed to the supporting surface by a number of bolts (12) fixed in the supporting surface, fixed to the bolts (12) by means of one or more discs (1) and a seal (2, 2') providing locking and sealing surface around the bolt (12) and the perforation of the lining (11), each with a through hole, intended to be threaded onto the corresponding bolt (12) and positioned on at least one side of the lining (11). The disk (1) is characterized in that the seal (2, 2') forms an integrated unit with the disc (1), wherein the seal (2, 2') only protrude on one side of the disk (1) intended to face towards the lining (11) where an inner seal (2) for sealing towards the bolt (12) projects, in axial direction, out(side) of an outer peripheral seal (2').