Floor and ceiling panel for use in buildings
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional construction methods are time-consuming and prone to waste and installation imperfections due to the linear sequence of activities by different trades, leading to cost overruns in building projects, especially in multi-unit buildings.
Innovation Solution
The development of pre-assembled floor and ceiling panels that include a frame, joists, a corrugated form deck, sound dampeners, and an in-floor radiant heat member, allowing for off-site assembly and efficient on-site installation, which supports uniform heating and reduces sound transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional construction methods are used with linear sequence of activities by different trades, then each trade can perform their specialized tasks, but the construction process becomes time-consuming and prone to waste and installation imperfections
Solution Approach 1:
The patent applies preliminary action by pre-assembling floor and ceiling panels in a factory setting before transporting them to the construction site. The panels are manufactured with integrated components including joists, subflooring, ceiling materials, insulation, and utility conduits already in place, eliminating the need for sequential on-site assembly by multiple trades and significantly reducing construction time.
Solution Approach 2:
The patent merges multiple construction elements into a single integrated panel system. Floor joists, subflooring, ceiling panels, insulation material, and utility conduits are combined into one pre-assembled unit that functions as both floor and ceiling structure, reducing the number of separate installation steps and improving overall construction efficiency.
2Ease of manufacture
If conventional construction methods are used with multiple trades working sequentially, then each trade can install their components, but installation imperfections and waste increase
Solution Approach 1:
The panel system performs preliminary assembly in a controlled factory environment where precision installation can be ensured. All components are pre-positioned and secured with appropriate fasteners and connections before shipping, guaranteeing installation precision that would be difficult to achieve through sequential on-site assembly by multiple trades.
Solution Approach 2:
The integrated panel serves multiple functions simultaneously - structural support, flooring, ceiling, insulation, and utility routing - all achieved through a single installation process. This multi-functionality eliminates the need for multiple specialized trades and reduces the risk of installation imperfections associated with coordinating multiple contractors.
3Productivity
If pre-assembled floor and ceiling panels are used, then construction time is reduced and waste is minimized, but the complexity of panel design and assembly increases
Solution Approach 1:
The building system is segmented into standardized modular panels that can be manufactured independently and assembled systematically on-site. Each panel is a self-contained unit with defined dimensions and integrated components, allowing for simplified production processes and easier quality control despite the complexity of the integrated design.
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
This solution streamlines the construction process, reduces waste and installation errors, and provides uniform heating while meeting sound and structural requirements, thereby enhancing efficiency and reducing costs in building projects.
Implementation Method 1
an in-floor radiant heat member disposed between the corrugated form deck and the ceiling substrate
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Floor and ceiling panels and methods of constructing a floor system for a building are described. In some embodiments, a panel includes a plurality of joists, a corrugated form deck disposed above and attached to the plurality of joists, a ceiling substrate disposed below and attached to the plurality of joists, and an in-floor radiant heat member disposed between the corrugated form deck and the ceiling substrate. In some embodiments, the panel includes a plurality of joists, a corrugated form deck disposed above and attached to the plurality of joists, and a sound dampener disposed between the corrugated form deck and the plurality of joists. In some embodiments, the method includes attaching a pre-assembled panel to a frame of the building and pouring concrete onto the panel so that a radiant heat member is separated from the concrete by a corrugated form deck of the panel.