Floor Construction Using Segmented Planks and Lightening Blocks
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Solution Overview
Problem
The existing methods for constructing floors using wooden planks and polystyrene foam blocks are cumbersome due to the need for precise measurement, manual gluing, and lengthy drying times, making them inefficient and time-consuming.
Innovation Solution
A method utilizing smaller, easier-to-move wooden planks that hold polystyrene blocks in place without glue, allowing for alternating block placement and eliminating the need for precise measurement, with concrete casting fixing the blocks and reinforcing elements directly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a wooden plank layer is used to support polystyrene blocks, then the floor structure provides sufficient support, but the wooden plank layer becomes voluminous and complicated to move
Solution Approach 1:
The invention divides the continuous wooden plank layer into individual separate planks. Each plank is a discrete unit that can be easily moved and positioned independently, eliminating the complexity of handling large wooden layers while maintaining structural support functionality.
2Manufacturing precision
If polystyrene blocks are positioned on the wooden plank layer with precise measurement, then channels of constant width are guaranteed, but the process takes time to accomplish
Solution Approach 1:
The planks are arranged in advance to form a grid pattern with predetermined spacing before the polystyrene blocks are placed. This preliminary arrangement of planks creates ready-made channels, eliminating the need for time-consuming measurements during block positioning while ensuring constant channel width.
3Stability of the object's composition
If glue is applied to fix polystyrene blocks to the wooden plank layer, then the blocks are prevented from displacing, but manual labour and drying time are required
Solution Approach 1:
The invention removes the glue application step entirely from the construction process. Instead of using adhesive, the design relies on the mechanical interlocking between the planks and blocks, where the planks physically hold the blocks in position without requiring chemical bonding or drying time.
4Stability of the object's composition
If manual gluing of polystyrene blocks is performed, then the blocks are fixed to the wooden layer, but the process requires manual labour and time
Solution Approach 1:
The plank structure is designed to automatically hold the polystyrene blocks in position through its geometric configuration. The planks serve their own function of securing blocks without requiring external adhesive materials or manual gluing operations, thereby increasing construction productivity.
Data Source
Figure 1
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AI summary
A method is disclosed for realising a floor and a floor obtained using the method. The method comprises steps of: positioning the first plurality of planks (9) and the plurality of blocks of lightening material (5) in such a way that: they are flanked to one another; they contact one another; they are aligned with respect to a same horizontal plane (H); each block of lightening material (5) of the plurality of blocks of lightening material (5) can be held still by at least two planks of the first plurality of planks (9) which are opposite one another; a containing surface (3) is defined for a casting of concrete (2); fixing the first plurality of planks (9) to one another and/or to a frame; fixing a plurality of reinforcing elements (4) to the first plurality of planks (9); arranging a plurality of containing walls (16) for a casting of concrete (2), which emerge from the horizontal plane (H) and which surround the containing surface (3) to define, with the containing surface (3), a containing volume (27); casting concrete into the containing volume (27) so as to fix the plurality of blocks of lightening material (5) and the plurality of reinforcing elements (4) to one another.