Deck Block Drainage and Interlocking Grooves
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Solution Overview
Problem
Existing insulated deck block systems suffer from unwanted liquid buildup and high costs due to the need for additional structural support members like T-shaped or I-beam support members, which can be detrimental to the performance and safety of concrete flooring and roofing systems.
Innovation Solution
A deck block system with integrated liquid drainage and support features, formed from fire-retardant expanded polypropylene or other suitable polymers, featuring projections and openings for interlocking, frusto-conical grooves for support retention, and a drainage system that allows condensate to flow through tapered openings and intersecting grooves, eliminating the need for costly support members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional interlocking block systems are used to form insulated decking, then structural support is provided through projections and grooves, but liquid condensate builds up and traps within the blocks causing performance and safety issues
Solution Approach 1:
The block is divided into functional zones: interlocking zones (projections and grooves) and drainage zones (tapered openings and channels). This segmentation allows the block to simultaneously provide structural support and liquid drainage, preventing condensate accumulation while maintaining interlocking capability.
Solution Approach 2:
The drainage system acts as an intermediary element within the block structure. The tapered openings and internal channels serve as intermediate pathways that capture and redirect liquid condensate away from the interlocking surfaces and insulated deck interior, preventing harmful liquid buildup.
2Strength
If T-shaped or I-beam support members are added between courses of blocks to provide additional structural support, then structural strength is improved, but fabrication and construction costs increase
Solution Approach 1:
The support function traditionally provided by separate T-shaped or I-beam members is merged into the block itself. The block's internal structure, including tapered openings and grooves, is designed to provide both interlocking capability and structural support, eliminating the need for additional support members and reducing fabrication and construction costs.
Solution Approach 2:
The block is designed as a multi-functional element that simultaneously provides: (1) insulation, (2) interlocking between blocks, (3) structural support between courses, and (4) liquid drainage. This universality eliminates the need for specialized support members, simplifying the system and reducing costs.
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 deck block system effectively drains liquids and provides structural support without the need for additional support members, enhancing the safety and performance of concrete flooring and roofing while reducing construction costs.
Implementation Method 1
a drainage system that allows condensate to flow through tapered openings and intersecting grooves
Data Source
AI summary
A deck block adapted to be interconnected with other deck blocks to form an insulating deck for casting concrete. The deck block comprising a foam panel at least one hole extending into the panel from the one end toward an opposing end such that the hole has an open end and a closed end. At least one protrusion extends from the panel and the protrusion is matingly receivable in at least a portion of a hole of a like panel to interconnect the panels in an end-to-end relationship. The panel has a vertical groove extending from a bottom surface and intersecting the opening of the panel to provide a fluid flow channel from the opening to the bottom surface of the panel when the like panels are interconnected. The protrusion has a horizontal groove extending along a lower end thereof from a distal end of the protrusion to a proximal end thereof so as to intersect the vertical groove.