Composite Floor Element with Integrated Metal Reinforcement

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Solution Overview

Problem

Existing load-bearing construction elements made of expanded plastic materials, such as foamed polystyrene, face limitations in load-bearing characteristics, leading to the need for temporary supports during installation of longer floor sections, increasing labor and costs.

Innovation Solution

A composite construction element featuring an elongated body of expanded plastic material with a longitudinal channel for concrete casting and a reinforcement metal structure with free ends, allowing the element to be supported by the metal structure rather than the plastic body, thereby reducing the need for temporary supports and simplifying installation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If construction elements made of expanded plastic material are used, then lightness and low cost are achieved, but load bearing characteristics are limited

Engineering Contradiction:

Improveweight of construction elementVSAvoidload bearing characteristics

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent combines expanded plastic material (for lightness and insulation) with metal reinforcing section bars (for strength) to create a composite construction element that achieves both light weight and adequate load bearing capacity. The metal bars are integrated within the expanded plastic body during forming operations.

Inventive Principle:

Principle #40Composite materials

2Weight of moving object

If construction elements with limited load bearing characteristics are used, then lightness is maintained, but temporary supports are required for longer floor sections, increasing labor and costs

Engineering Contradiction:

Improveweight of construction elementVSAvoidneed for temporary supports

Core Design Contradiction:

Weight of moving objectVSDevice complexity

Solution Approach 1:

The metal reinforcing section bars are pre-integrated into the expanded plastic construction elements during manufacturing. This preliminary reinforcement allows the elements to bear their own weight and support floor loads without requiring additional temporary supporting elements during installation, even for longer floor sections.

Inventive Principle:

Principle #10Preliminary action

3Strength

If temporary supports are arranged under floor structure, then load bearing capacity is ensured, but labor and manufacturing costs increase

Engineering Contradiction:

Improveload bearing capacityVSAvoidmanufacturing cost and labor

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The construction elements are designed to be self-supporting through the integrated metal reinforcing section bars. The elements can bear their own weight and contribute to the floor structure without requiring external temporary supports, thereby reducing labor and manufacturing costs while maintaining adequate load bearing capacity.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS7784235B2Load bearing construction element, in particular for manufacturing building floors, and floor structure incorporating such element

Publication Date: 2010.08.31 PLASTEDIL

AI summary

A composite construction element (2) particularly useful for manufacturing building floors, comprises:a) an elongated body (3) made of expanded plastic material, provided with at least one longitudinal channel (4) open on the upper side for receiving a concrete casting (5);b) a reinforcement metal structure (11) of the casting (5), housed in the longitudinal channel (4), associated to the elongated body (3) and having opposite free ends (12) protruding from longitudinally opposite parts of the elongated body (3) for a portion of predetermined length.Advantageously, the composite construction element (2) possesses optimum load bearing characteristics, lightness and flexibility of use.