Sealing Compound for Automated Multi-Layer Concrete Production
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Solution Overview
Problem
The production of multi-layer concrete elements is largely manual and inflexible, with existing methods requiring separate formliners, sand beds, or sealing foils, which limit automation and result in concrete penetration into joints, causing contamination and additional cleaning steps.
Innovation Solution
Applying a non-bonding sealing compound in strips on the production table to seal joints automatically, allowing for robotic application and easy removal, and using anchoring rods with insulating layers to create a solid sandwich composite.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual production methods with sand beds or sealing foils are used, then joints can be sealed, but the production process becomes time-consuming and difficult to automate
Solution Approach 1:
The sealing compound is applied to the production table before the cladding panels are positioned, creating pre-formed sealing strips that automatically seal joints when panels are placed. This preliminary action eliminates the need for manual sealing operations during assembly and enables robotic automation.
Solution Approach 2:
A sealing compound consisting of non-bonding aggregate particles serves as an intermediary material between the production table and cladding panels. This intermediary automatically seals joints and prevents concrete penetration without requiring manual intervention or complex sealing mechanisms.
2Productivity
If matrices, sand beds, or sealing foils are used to seal joints, then concrete penetration is prevented, but these methods require additional materials and manual operations
Solution Approach 1:
The harmful function of matrices, sand beds, and sealing foils is extracted and replaced by a simplified sealing compound system. The sealing compound consists of non-bonding aggregate particles that perform the sealing function without requiring complex supporting structures or manual application procedures.
Solution Approach 2:
The sealing compound uses non-bonding aggregate particles with specific physical properties (non-adhesive surface characteristics) that fundamentally change the interaction between the sealing material and concrete, preventing penetration without requiring additional bonding mechanisms or complex material systems.
3Object-generated harmful factors
If concrete is applied directly without sealing, then the production process is simplified, but concrete penetrates into joints and causes contamination requiring additional cleaning operations
Solution Approach 1:
The sealing compound is applied in advance to create a protective barrier that prevents concrete from penetrating into joints. This preliminary protective action eliminates the need for subsequent cleaning operations and prevents contamination before it occurs.
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
Enables automated production of multi-layer concrete elements with sealed joints, preventing concrete penetration and simplifying the process, reducing contamination and post-processing efforts, while allowing for flexible production and improved panel protection.
Implementation Method 1
The sealing compound applied in strips compensates for tolerances of the production table on the one hand and has a vibration-dampening effect on the other, so that the cladding panels are protected from damage when the concrete layer is subsequently compacted.
Implementation Method 2
Anchoring rods are used to connect the individual layers. For this purpose, holes are drilled into the insulating layer before it is inserted into the formwork frame; after insertion into the formwork frame, an anchoring rod is inserted into each hole, which engages in the not yet hardened concrete layer and protrudes with its end facing away from it over the insulating layer
Data Source
Figure 1~4
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Figure 9~11
AI summary
The method involves placing cladding panels (16) on a production table under release of joints arranged next to each other in a formwork frame. Edges of the panels are pressed into strips (14) on all sides to apply a concrete layer (28) on the panels. A sealing compound present in the strips is applied on the table, where a position of the compound corresponds to a pattern of the joints. An insulating layer (34) is applied on the concrete layer. Boreholes are attached to the insulating layer to insert an anchoring rod (36) into each borehole after inserting the insulating layer into the frame.