PREFABRICATED ELEMENT CONTAINING A PERMANENTLY EMBEDDED SIGN AND THE PRODUCTION METHOD OF PREFABRICATED ELEMENT

Abstract

 Prefabricated element (12) containing a permanently embedded sign or its part (14), characterized by the fact that at least one surface of the element (12) has a cut (20) in the shape of the sign or its part (14), whereas inside the cut (20) is permanently embedded photoluminescent mass (22) which is flush with the external surface of the element (12). Production method of the element, according to which, in the first place the element (12) with the cut (20) is prepared and later the cut (20) is cleaned and dried. Next, it is primed and painted with reflective paint suitable for the photoluminescent mass (22) and into the cut (20) the fresh photoluminescent mass (22) is placed and left until it hardens.

Description

[0001] The invention relates to a prefabricated element in the form of a complete element which contains a permanently embedded, photoluminescent sign of any shape - be it a pictogram, a geometric figure, a line, a digit or a sequence of them, as well as the production method of the element in question. The solution provided by the invention can have its application as a energy-saving information sign, a mandatory sign, a prohibitory traffic sign or a warning sign, signs increasing safety and facilitating transport, especially after dark, on all kinds of hardened surfaces i.e. traffic and transport routes, bike paths, alleys, on parking lots, pavements, quays, railway platforms, swimming pools' edges, stairs, stairwells as well as in other applications tailored to meet specific needs. The prefabricated element can also serve as a decorative or identification element in gardens, parks, public spaces, cemeteries, in front of the main entries to buildings and it can also be a marketing tool when it contains a logo or a slogan.

[0002] The surrounding space contains a lot of signs and elements aimed at ensuring safety, facilitating transport, transmitting information and making our surroundings functional and friendly. All those signs and elements are installed out of concern for all of us: drivers, cyclists, motorcyclists, pedestrians, the disabled, children and elderly people, tourists, foreigners and others. Most of those signs and elements are based on visual communication. After dark, however, its effectiveness decreases unless it is supported by electrical systems generating light which can illuminate given elements of visual communication. The cost of an electrical installation and energy consumption can be eliminated or limited due to the use of a photoluminescent pigment in the material which a sign is made of. Then, after exposing to light, signs will emit their own light thanks to which they will be visible after dark. Thus in some places it could be possible to get rid of electrical systems and, as a result, save significant amounts of money.

[0003] The state of the art includes combinations of photoluminescent materials with building materials. Such a solution is described by a Belgian patent description BE822626. According to it, a photoluminescent component is combined with building materials e.g. concrete in order to create a homogenous building material with photoluminescent properties.

[0004] A Chinese utility model in protective specification CN2718049 sets forth a prefabricated, glowing curb with a cable duct. The top outer part of the curb contains a concrete binder with a photoluminescent component.

[0005] Patent specification WO2010134805 presents the production method of concrete products whose surface is covered with a coating containing small, glowing pieces of glass. The glass contains a photoluminescent pigment and adheres to the concrete due to resin, glue or plastic.

[0006] Patent specification WO2014175732 provides the method of a photoluminescent marking of road lanes and lines. A cut is made in the surface of a road. Then an elastic section, which contains a photoluminescent material (with a source of light, too, if necessary), is placed inside the cut.

[0007] Patent specification EP2531655 shows markings placed on hardened surfaces by painting them with paint or by sticking on them tapes with a photoluminescent component.

[0008] Similarly, patent specification GB2224296 describes an invention in the form of a line made of plastic and epoxy paint stuck on road surfaces.

[0009] Patent specification JP4066051 presents an invention where concrete elements and photoluminescent markings are heat-sealed using a burner.

[0010] The efficiency and durability of the above described methods of installation, sticking, painting or heat-sealing of photoluminescent materials outdoors are dependent upon given weather conditions. The durability of markings is lowered due to the effect of humidity, frost or dirt during installation and painting works. The use of paints in outdoor conditions increases the risk of a leak into the natural environment and the contamination of soil and groundwater. Additionally, even a slight protrusion (0,3mm - 0,8mm) of markings above the road surface they are placed on, exposes them to abrasion. Consequently, markings need to be renewed even every six months. The comparison between the solution belonging to the state of the art and the concept developed by the invention is presented by fig.4 and fig. 4a respectively.

[0011] The subject of the invention solves the above mentioned problems: it eliminates the problem of marking abrasion and the dependency on favorable weather conditions during the installation process. The production of the invention takes place in an industrial plant, which facilitates the quality control of production processes and decreases the risk of environmental contamination. The technology of the invention provides unlimited possibilities of shaping photoluminescent signs on prefabricated elements.

[0012] The solution set forth by the invention, by embedding a marking made of photoluminescent mass in a properly shaped element, provides a durable prefabricated element performing the function of information, warning, prohibition, order or decoration. Due to their embedding in a properly prepared cut, photoluminescent markings gain a side construction protection, which increases their resistance to abrasion significantly in comparison with photoluminescent layers used on non-cut surfaces. Careful priming of the surface of a cut and covering it with reflective paint increases its intensity of reflecting light energy from the marking embedded in the cut, thus its functional efficiency is also increased. The production of prefabricated elements with photoluminescent markings in factory conditions, in a stable environment, makes the pace and the quality of production independent from weather conditions and it enables, to a greater degree, to prevent uncontrolled leaks of chemical substances into the natural environment. The invention is characterized by energy efficiency as it limits or eliminates the use of electrical energy which is necessary for it to perform its function after dark. The operational-functional readiness of prefabricated elements in a designated place depends only on the length of time of their installation, and not on the time of drying of photoluminescent material creating markings. The controlled conditions in the factory allow for the use of a wider spectrum of milling technologies to make cuts in the finished elements and for modeling formwork molds, as a result of which the choice of the shapes of photoluminescent signs is virtually unlimited. The factory conditions allow for producing repeatable elements distinguished by the best possible properties. The simplicity of the production technology makes it easier to ensure products' durability and is relatively inexpensive. The technology's durability contributes to the reduction of maintenance costs (i.e. renewal) of hardened surfaces, which should, in turn, contribute to the improvement of the safety of users of public spaces, in particular after dark.

[0013] The subject of the invention is characterized by the fact that a photoluminescent sign (or its part, if a given sign is bigger than a single prefabricated element) is permanently embedded in the element. The prefabricated element has a cut in the shape of a marking or its part in which photoluminescent mass is embedded. During the production phase it is preferable, once a fresh photoluminescent mass is hardened, for a sign to be flush with the external surface of the element.

[0014] It is preferable when the depth of a cut in the element is from 1 to 5 mm and the width from 5 to 100 mm and when the external surface of a cut is covered with reflective paint. Preferably, a lightning system should be installed on the surface of a cut. The use of a lightning system, e.g.in the form of LEDs embedded in the mass, additionally illuminates a photoluminescent sign from underneath. Any lightning system requires power supply, therefore the element should contain at least one opening for providing power supply. The cut of the said depth and width prevents spillages, dispersals and smears of a fresh photoluminescent mass during forming it into the shape of a given marking in the element and during transporting it within the premises of an industrial plant. Thus, during the production of prefabricated elements any potential loss of photoluminescent mass is minimized.

[0015] The precision of making the edge of a cut and filling it up with photoluminescent mass translates directly into increased visibility of a sign in prefabricated elements, which consequently translates into its clearness and effectiveness. The required precision depends on the distance from which a marking is supposed to be visible - it will be different for a prefabricated element placed in a pavement than for the one placed high in the elevation of a building. In every instance, the precision should very from 0,1 to 5 mm.

[0016] The edges of a cut and the marking protect one another from abrasive horizontal forces, which is presented by fig.4a and fig. 4b comparing the solution delivered by this invention with the solutions belonging to the state of the art. Abrasive forces exists in the city traffic e.g. vehicles' wheels running onto markings or shoe soles rubbing them off. In places of particularly increased pedestrian traffic e.g. stairs at railway stations, the cut provides a long-lasting protection of signs and they comfortable in daily use (signs are imperceptible under feet) and financial savings due to the fact that regular renewing of signs is unnecessary.

[0017] In a preferable variant, photoluminescent mass consists of a transparent synthetic mass resistant to UV rays mixed with a photoluminescent component. The synthetic mass performs the role of a binding agent.

[0018] Additionally, it is preferable when a photoluminescent component is in the form of compounds of rare earth elements with photoluminescent properties in light yellow, light green or light blue color and the granularity of 40-50 µm. In the daytime these compounds absorb light energy (by exposition to sunlight) and after dark they release it into the surrounding environment as a part of the visible spectrum. As the result of their absorption of light energy from any portion of the visible spectrum, ultraviolet or infrared, the photoluminescent component can glow even up to 12 hours, although the intensity of light weakens with time. It is preferable when the photoluminescent component added to the synthetic mass is compliant with norm DIN67510.

[0019] Photoluminescent mass can also contain quartz sand, powdered white glass of 0,05 - 0,3 mm fraction or additions in the form of glass microspheres from 125 to 850 µm in diameter. The higher the ratio of the amount of the synthetic mass to quartz sand, powdered glass, glass microspheres in the upper part of a given marking, the smoother and softer its surface becomes. Quartz sand (alternatively, powdered glass or glass microspheres) gives constructional strength to the mass - i.e. it constitutes its building material. In order to achieve a better exchange of light energy between the photoluminescent element and the environment, the building material should be transparently white. The more grains of quartz sand, powdered glass, glass microspheres in the upper part of a given marking, the rougher its texture becomes. It is also possible for photoluminescent mass to contain components with antifungal or antibacterial properties or components acting as filters changing the glow colour of markings or hardening components.

[0020] The subject of the invention also includes the method of producing prefabricated elements. The method is characterized by the fact that, in the first place, an element with a cut is prepared, and then the cut is cleaned and dried to be primed and painted with reflective paint suitable for the mass. Subsequently, the photoluminescent mass is placed permanently inside the cut and after hardening, it constitutes a embedded photoluminescent sign.

[0021] In a preferable variant of the method, an element is casted in a formwork mold, at the bottom of which a mold of the mirror image of the marking, or its part, is placed. Later, after a reinforcing mesh is placed, the mould is filled in or poured with a material mixture, preferably concrete. The material is condensed by vibrations and later left to harden.

[0022] It is preferable when both of the moulds are made of a non-porous and resistant to vibrations material. It is also preferable when the moulds are cleaned and spray-coated with an anti-adhesive oil in order to prevent the material mixture from sticking to them.

[0023] Another preferable variant of producing the prefabricated element according to the method is when a cut is made by mechanical processing with the use of a milling machine or an engraving machine. These machines receive data from a process-controlling computer based on a programmed project. This variant of the production method is intended for the materials not subject to plastic forming e.g. paving slabs.

[0024] It is preferable when photoluminescent mass, after being placed in a cut and hardening, is flush with the external surface of the element.

[0025] In the production method, it is also possible to use, as photoluminescent mass, a transparent synthetic mass resistant to UV rays and a photoluminescent component. The photoluminescent component can come in the form of rare earth elements with photoluminescent properties. Optionally, what can be added to photoluminescent mass is quartz sand or powdered glass of 0,05 - 0,3 mm fraction or additions in the form of glass microspheres from 125 to 850 µm in diameter, or components with antifungal or antibacterial properties or components acting as filters changing the glow colour of markings or hardening components. The additions to photoluminescent mass are aimed at providing durability of a sign, roughness of its surface, its reflectiveness or other properties depending on specified requirements.

[0026] The subject of the invention and its production method are presented in the following figures: fig.1 shows an axonometric view of the prefabricated element with a photoluminescent sign as an example; fig.2a - a cross-section of the cut with photoluminescent mass in the element; fig.2b - a cross-section of the cut with photoluminescent mass in the element with a duct for an additional light source system; fig.3a - a projection of the prefabricated element in the form of a concrete slab with a photoluminescent pictogram in the shape of a bike; fig.3b - a projection of the prefabricated element in the form of two adjoining concrete slabs, which, as a result, creates a bigger photoluminescent sign in the shape of a bike; fig.4a - a side view of a wheel running over the sign in the cut; fig.4b - a side view of a wheel running over the sign placed on the surface and a distribution of forces; fig.5 - a cross-section of the moulds prepared for casting an prefabricated element; fig.6a - a cross-section of the cut with a fresh photoluminescent mass before the vibration process; fig.6b - a cross-section of the cut with a fresh photoluminescent mass after the vibration process.

[0027] Prefabricated element 10 consisting of element 12 with photoluminescent sign 14 whose example is shown in fig.1, constitutes a fragment of a horizontal hardened surface - for example, prefabricated element 10 can be embedded in the surface of a bike path. Prefabricated element 10 consists of element 12 in the form of a slab and sign 14 made of photoluminescent mass 22 permanently embedded in cut 20 in element 12. Model sign14 is in the shape of a bike pictogram.

[0028] Fig.3a shows a projection of the prefabricated element according to fig.1, whereas fig.3b presents a projection of prefabricated elements placed side by side, as a result of which one photoluminescent sign 14 is obtained in the shape of a bike.

[0029] The use of cut 20 has two advantages:

• it gives fresh photoluminescent mass 22 the form of sign 14,
• it protects sign 14 from destructive horizontal forces 40 shown in fig.4a, b.

[0030] Cut 20, in the example of embodiment, has the depth of 5 mm and the width of 70 mm, while the inner surface of cut 20 is coated with reflective paint 210.

[0031] Photoluminescent mass 22 consists of synthetic mass 214 resistant to UV rays mixed with photoluminescent component 216. Photoluminescent component 216 contains a compound of rare earth elements with the granularity of 50 µm.

[0032] Moreover, photoluminescent mass 22 contains quartz sand, powdered white glass 212 with the fraction of 0,3 mm and glass microspheres of 125 µm in diameter. Additionally, photoluminescent mass 22 contains components with antifungal or antibacterial properties, hardening agents as well as a component acting as the filter changing the glow colour of a marking.

[0033] In a different version of cut 20, inner surface of cut 20 is coated with reflective paint 210, and on the surface of reflective paint 219 a lightning system is placed in the form of LEDs 218 together with power cord 220 through an opening in element 12.

The example of a patent application method no. 1

[0034] In the first place, element 12 with cut 20 is prepared. In elements 12 formed in a plastic way, e.g. from reinforced concrete, element 12 is prepared using moulds and casting techniques.

[0035] First, the formwork mould of element 50 is made separately and the formwork mould of the mirror image of sign 52 is prepared, as shown in fig.5. Both of the moulds are made of a non-porous material, resistant to vibrations. The mould of the mirror image of sign 52 is made from an acrylic plate, 3 mm thick, stabilized to avoid any movement during making a cast and later, during the vibration process. The stability is achieved by sticking the plate to the bottom of the mould. Before the material mixture is placed in the mould of element 50 and reinforcement is set in mould 50, the mould are cleaned and coated with an anti-adhesive oil 54. Later, when the reinforcement is set and immobilized in mould 50, an earlier prepared material e.g. concrete is placed inside the mould of element 50. At this stage, the mould of element 50 is vibrated for a short time in order to thicken the inserted material, to obtain level edges 24 and a level shape of cut 20 and to remove air gaps, as shown in fig.6a and 6b. Air gaps are highly undesirable as they weaken the construction of element 12, make it possible for moisture to build up, create the risk of reinforcement corrosion. Moreover, water frozen inside air gaps can burst sign 14 and element 12. The vibration process should not take too long as it can delaminate the material element 12 is made of. Next, the filled-up mould is left for the time necessary for the material to harden. Once the material is hard, element 12 with a prepared cut 20 is taken out of the mould and it goes through quality control and, if necessary, correction are made.

[0036] After element 12 with cut 20 is made, element 12 undergoes a further processing. Before cut 20 is filled up with fresh photoluminescent mass 22, it should properly be prepared. First, cut 20 is cleaned of dust and degreased. Next, cut 20 is primed with colourless priming agent 28. When priming agent 28 is dried, a single layer of white reflective chemically-resistant priming paint 210 for concrete is applied on it.

[0037] Sign 14 is made of fresh photoluminescent mass 22 inserted into cut 20. For the comfort of end users, it is preferable when vehicles running over horizontal signs 14 and pedestrians walking over them cannot sense any irregularities at the junction of sign 14 with element 12 or any difference in texture between them. In particular cases, the protuberance of sign 14 over element 12 can be justified e.g. in order to draw special attention to a given sign. Nevertheless, in the example of a patent application, photoluminescent mass 22 in cut 20 is flush with the surface of element 12.

[0038] The surface of element 12 and sign 14, in the example of a patent application, were given an anti-slip texture. Optionally, element 12 or sign 14 can be smooth.

[0039] Photoluminescent mass 22 consists mainly of synthetic mass 214 and photoluminescent component 216, whereas photoluminescent component 216 is comprised a compound of rare earth elements. Quarts sand and powdered glass 212 of 0,05 mm fraction and glass microspheres of 850µm in diameter, hardening and antifungal substances were also added to photoluminescent mass 22.

[0040] Fresh photoluminescent mass 22 is poured into cut 20 in such a way that:

• the mass is evenly distributed,
• there are no air gaps,
• the surface is level,
• material waste is minimal,
• no external surfaces of element 12 gets stained in the process.

[0041] After inserting fresh photoluminescent mass 22 into cut 20, prefabricated element 10 should be left until sign 14 gets hardened, it should stay in a stable and clean environment. After hardening, prefabricated element 10 is ready for its installation in a designated place.

The example of a patent application method no. 2

[0042] In the first place, element 12 with cut 20 is prepared. In case of element 12 being made of stone, cut 20 is made by mechanical processing using e.g. a milling machine. The milling machine receives data from a computer which is equipped with software for designing signs 14 and the one for controlling the milling process. A designer uses the software to determine, among others, the location and dimensions and shape of cut 20 on a computer model of element 12. After cut 20 is milled, it is cleaned and dried and then it is coated with reflective priming paint. Once the paint is hardened, but still before it is completely dried, fresh photoluminescent mass 22 is inserted in cut 20 and when the mass is hard, it constitutes sign 14 embedded in cut 20.

[0043] The advantage of the prefabricated element is: the darker it gets, the brighter the sign glows. Thus, as people's alertness weakens, the visual message, which is the function of the element, directed to them gets stronger. It translated positively into safety and lives of people who are in the vicinity of signs e.g. pedestrians, cyclists, the disabled, drivers. Thanks to that, everyone feels safer in the space they happen to be. For 6 hours after dark, signs glow very intensively e.g. a pedestrian crossing marked with them can be visible even from the distance of a few hundred meters. Additionally, late at night on the road, the photoluminescent component is illuminated temporarily by the lights of passing vehicles and gives out light for a short time afterwards.

[0044] Another advantage of the prefabricated element being the subject of the invention is the fact that it performs its informative, warning, mandatory, prohibitive, or decorative function without electricity consumption. What it means is huge savings at the investment stage because the owner does not have to incur the costs of arranging, designing and building additional electrical installations and protecting them from being accessed by unauthorized persons e.g. thieves. During daily use, the owner of prefabricated elements does not incur the cost of electricity, for which he would need to pay in case of standard illuminated signs.

[0045] Moreover, photoluminescent signs are unfailing - they never stop working during a power cut, or when a short-circuit occurs, or when cables are cut. The key to their reliability is in the laws of physics, chemistry and in their durable construction - hence the idea to produce prefabricated elements in an industrial plant, in stable and controlled conditions.

[0046] Another advantage of the invention is its pro-ecological nature which also includes, mentioned earlier, energy efficiency. Moreover, the use of prefabricated elements instead of paints applied on site eliminates the emission of paints' ingredients into the environment and also eliminates the risk of an uncontrolled spillage of paints and their penetration into groundwater. The durability of prefabricated elements, higher than the durability of paints, enhances these advantages as paints need to renewed, on average, every six months. As a result, every six months thinners are emitted, which creates the risk of their penetration into the environment.

[0047] Another advantage of the invention is time savings during construction of hardened surfaces such as roads, pavements, parking lots or stairs. In case of the necessity to paint or stick signs on these surfaces, a contractor would have to devote time at least for preparing the surface (cleaning, degreasing), painting or sticking, securing it for the time necessary for markings to dry. In addition, these actions may be extended due to unfavourable weather conditions e.g. rain or frost. Prefabricated elements are ready to be used immediately after installation and it takes the same amount of time as installing elements without markings. Thus, it is safe to assume that, in case of marking the surface only with prefabricated elements, the time of making markings equals zero. It is of great importance in case of major traffic routes which are vital for an uninterrupted functioning of cities.

[0048] The solution according to the invention has a wide range of applications in marking and securing spaces. Additionally, the solution can be used for decorating and for marketing purposes. Moreover, prefabricated elements can be divided into the following groups:

• Information signs; e.g..: P - a parking lot, bike sign - a bike path, number - a distance, zebra - a pedestrian crossing, etc.
• Warning, prohibitive or mandatory signs; e.g..: line - a change of the surface's purpose, a change of height e.g. prefabricated stairs, stop sign - an order to stop, inscription "attention!" - a warning, etc.
• Decorative elements; e.g.: elevation panels with a embedded sign in the shape of a line as an ornament of the building's edge, parking posts with embedded signs - patterns of any shape, etc.
• Special signs; np.: logo - the marking of a company's headquarters, etc.

[0049] The above description of the invention presents the best possible and the most up-to-date, as of the moment of preparing the description, methods of production and applications, which does not exclude other variants, combinations and equivalents of the productions methods and applications of the invention. Therefore, the invention is not restricted to the above described production methods and examples of application, but to all the possible production methods and applications within the nature of the invention.

Claims

1. Prefabricated element containing a permanently embedded sign or its part, characterized in that at least one of the surfaces of prefabricated element (12) has a cut (20) in the shape of the sign or its part (14), whereas in the cut (20) photoluminescent mass (22) is permanently embedded and it is flush with the external surface of the element (12).

2. Prefabricated element according to claim 1 characterized in that, the cut (20) in the element (12) has depth ranging from 1 to 5 mm and the width from 5 to 100 mm, whereas the internal surface of the cut (20) is coated with reflective paint (210), on the surface of which a lightning system is placed, while the element (14) has at least one opening for providing power supply to the light system.

3. Prefabricated element according to claim 1 or 2 characterized in that, the photoluminescent mass (22) consists of synthetic mass resistant to UV rays (214) mixed with a photoluminescent component (216).

4. Prefabricated element according to claim 1, 2 or 3 characterized in that, the photoluminescent component (216) comprises of the compounds of rare earth elements with photoluminescent properties in light yellow, light green or light blue colour, the granularity of 40-50 µm compliant with norm DIN67510.

5. Prefabricated element according to claim 1, 2, 3 or 4 characterized in that, the photoluminescent mass (22) contains quartz sand or powdered white glass (212) with the fraction of 0,05 - 0,3 mm or glass microspheres with the diameter from 125 to 850 µm or components with antifungal and antibacterial properties or components acting as filters changing the glow colour of a given sign or hardening components.

6. Production method of prefabricated element characterized in that, the element (12) with the cut (12) is prepared and later the cut (20) is cleaned and dried, in next step it is coated with reflective paint suitable for the photoluminescent mass (22) and into the cut (20) the fresh photoluminescent mass (22) is placed permanently and is left till it gets hardened.

7. The method according to claim 6 characterized in that, at the stage of preparing the element (12) with the cut (20), the element is cast in a formwork mould (50), at the bottom of which the mould of the mirror image of the sign, or its part, is placed and then after setting reinforcement mesh, the mould is filled in or poured with a plastic material mix, preferably concrete, then the material is thickened during the vibration process and is left until it gets hardened.

8. The method according to claim 7 characterized in that, both of the moulds are made of a non-porous material, resistant to vibrations, and the moulds are cleaned and spray-coated with an anti-adhesive oil.

9. The method according to claim 6 characterized in that, at the stage of preparing the element (12) with the cut (20), the cut (20) is made by mechanical processing of the element (12) with the use of a milling machine or an engraving machine.

10. The method according to claim 9 characterized in that, a milling machine or an engraving machine receives data from a computer which controls the process of milling or engraving based on a programmed project of a given sign or its part (14).

11. The method according to claim 6, 7, 8 or 9 characterized in that, the surface of the photoluminescent mass (22) is flush with the external surface of the element (12).

12. The method according to claim 6, 7, 8, 9, 10 or 11 is characterized in that, a transparent synthetic mass resistant to UV rays (214) and the photoluminescent component (216) are used as the photoluminescent mass (22), whereas the photoluminescent component (216) is comprised of the compounds of rare earth elements with photoluminescent properties.

13. The method according to claim 6, 7, 8, 9, 10, 11 or 12, characterized in that quartz sand or powdered glass (212) with the fraction of 0,05 - 0,3 mm or glass microspheres with the diameter from 125 to 850 µm or components with antifungal and antibacterial properties or components acting as filters changing the glow colour of a given sign or hardening components.

Drawing