Foam-Filled Structural Plank Foundation for Moisture-Resistant Support
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional building foundations made of concrete are environmentally damaging, require multiple materials and supplies, and have unpredictable strength development, leading to increased construction time and costs.
Innovation Solution
A foam-filled structural plank building foundation using expanded polystyrene foam with a steel or aluminum cage, allowing pre-assembly in a factory and rapid installation, eliminating the need for concrete and enabling predictable strength and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional concrete slabs or timber frames are used for building foundations, then structural strength is provided, but moisture from the ground can penetrate through to the timber causing rot and decay
Solution Approach 1:
The patent implements a nested foundation structure where the impermeable membrane is placed within the void space of the cellular concrete blocks, and the reinforcement mesh is positioned within the membrane. This nested arrangement protects the timber from moisture while maintaining a relatively simple overall foundation structure, resolving the contradiction between moisture protection and structural complexity.
Solution Approach 2:
The impermeable membrane acts as an intermediary barrier between the ground moisture and the timber foundation elements. This intermediate layer prevents direct contact between moisture and timber, providing reliable moisture protection without requiring complex foundation designs.
2Quantity of substance
If conventional concrete blocks with voids are used, then material usage is reduced, but the voids can allow moisture penetration and reduce structural integrity
Solution Approach 1:
The impermeable membrane is nested within the void spaces of the cellular concrete blocks, converting previously harmful voids into protective chambers. This maintains the material efficiency of cellular concrete while eliminating moisture penetration risks through the voids.
Solution Approach 2:
The patent converts the harmful void spaces in conventional concrete blocks into beneficial moisture-trapping chambers by lining them with impermeable membrane. The voids that would normally allow moisture penetration are transformed into protected spaces that enhance moisture resistance while maintaining material efficiency.
3Strength
If reinforcement is added to concrete blocks to improve strength, then structural integrity increases, but the complexity of manufacturing and assembly increases
Solution Approach 1:
The reinforcement mesh is pre-positioned within the impermeable membrane before the concrete blocks are assembled. This preliminary action simplifies manufacturing by integrating reinforcement placement into the membrane installation process, rather than requiring separate reinforcement operations after block assembly.
Solution Approach 2:
The patent merges the reinforcement function with the membrane installation process. The reinforcement mesh is incorporated into the membrane layer, combining two functions (moisture protection and structural reinforcement) into a single integrated assembly step, thereby reducing manufacturing complexity.
4Use of energy by moving object
If timber is used in contact with ground, then natural insulation is provided, but moisture causes rot and decay reducing durability
Solution Approach 1:
The impermeable membrane serves as an intermediary barrier between ground moisture and the timber foundation elements. This intermediate layer maintains the thermal insulation benefits of timber while protecting it from moisture-induced rot and decay, thereby extending the timber's service life.
Solution Approach 2:
The timber elements are nested within the protected void spaces created by the membrane-lined concrete blocks. This nested arrangement positions the timber in a moisture-protected environment while maintaining thermal insulation performance, resolving the contradiction between insulation and durability.
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A foam filled structure plank made from a plurality of structural beams assembled together to form a structure capable of supporting the weight of a building thereon, wherein the plurality of structural beams define an enclosure therebetween and an outer perimeter therearound; and a structural building foam such as having expanded polystyrene foam having a density from 1.5 to 3.0 PFC filling the enclosure.