Secure Enclosure Using Plastic Shell and Polymer Concrete
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Solution Overview
Problem
Conventional composite safes for housing valuable components like ATMs are expensive to manufacture due to the use of steel inner and outer layers and cement-based concrete, which also results in a heavy and cumbersome structure.
Innovation Solution
A method of constructing a secure enclosure using a moulded plastic shell body with mesh reinforcement, filled with quick-setting polymer concrete, eliminating the need for steel layers and reducing manufacturing costs and weight by using a moulded plastic shell body with a C-shaped protrusion for concrete adhesion and a surface decoration for aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel inner and outer layers are used in composite safes, then strength and security are improved, but manufacturing cost and weight increase
Solution Approach 1:
The patent changes the material parameters from traditional steel to a composite system of plastic shell + foam core + concrete layer. This parameter change maintains structural strength while significantly reducing weight and manufacturing cost. The plastic shell provides the basic structural framework, foam core adds insulation and structural integrity, and concrete layer provides the necessary security and weight without requiring thick steel plating.
Solution Approach 2:
The patent employs a composite material structure consisting of multiple layers: plastic shell, foam core material, and concrete coating. This composite approach combines the advantages of each material - plastic for lightweight structure, foam for insulation and structural support, and concrete for security and weight - achieving both strength reduction and cost reduction simultaneously.
2Reliability
If steel layers and cement-based concrete are used, then security and durability are improved, but manufacturing cost increases
Solution Approach 1:
The patent changes the material parameters from expensive steel and cement-based concrete to more economical alternatives. The plastic shell with foam core and concrete coating provides equivalent or superior security at lower cost. The concrete layer, when applied to the foam-core structure, achieves the necessary security rating without requiring the expensive steel sandwich construction.
Solution Approach 2:
The patent uses cheaper materials (plastic, foam, concrete) that can be easily manufactured and replaced if needed, rather than investing in expensive steel construction. The moulded plastic shell with integrated features allows for cost-effective production and potential replacement without significant investment.
3Stability of the object's composition
If conventional steel and concrete construction is used, then structural integrity is improved, but construction time and complexity increase
Solution Approach 1:
The patent applies preliminary action by pre-moulding the plastic shell with integrated features (protrusions, recesses, channels) before assembling the final structure. The foam core is pre-positioned within the shell, and the concrete layer is pre-applied to create the finished enclosure. This eliminates on-site construction steps and reduces assembly time significantly.
Solution Approach 2:
The patent merges multiple construction steps into a single integrated process. The plastic shell is moulded with integrated mounting features, the foam core is positioned and bonded, and the concrete layer is applied in one continuous manufacturing process, creating the complete secure enclosure body without requiring separate assembly steps for each component.
4Strength
If steel layers are used to create cavity for concrete, then structural strength is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The patent extracts the steel layers from the construction process entirely, replacing them with a plastic shell structure. The cavity for concrete is not created by steel framing but by the moulded plastic shell itself, which integrates the structural framework and concrete-forming cavity into a single component, eliminating the need for separate steel layer assembly.
Solution Approach 2:
The patent uses composite materials (plastic shell + foam core) to replace the steel structure that would traditionally create the concrete cavity. The foam core material provides both structural support and the necessary cavity formation, eliminating the need for steel framing and simplifying the construction process.
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 method reduces construction time and costs, results in a lighter and more efficient secure enclosure with improved adhesion between plastic and concrete, and provides a decorative finish, making it easier to handle and ship.
Implementation Method 1
quick-setting polymer concrete has been inserted into the cavity and has adhered to the moulded plastic shell body
Data Source
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AI summary
A method of constructing a secure enclosure body (150) is disclosed. The method comprises providing a moulded plastic shell body (100) incorporating a mesh reinforcement (114); coupling a mould to the moulded plastic shell body (100) to define a cavity between the mould and the moulded plastic shell body (100); inserting concrete into the cavity; and removing the mould when the concrete has sufficiently set to provide a secure enclosure body (150).