Foamed Cement Floor Panel with Metal Plates
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Solution Overview
Problem
Conventional floor panels made of concrete or steel with lightweight concrete require complex production processes and increased costs due to the need for metal reinforcing materials and leakage prevention, making them difficult to produce and lightweight, while also being prone to damage during transport and use.
Innovation Solution
A floor panel comprising a foamed cement board with a porous hardened cement phase and dispersed fibers, topped and bottomed with thin metal or stone plates, which are adhesive-attached, providing the necessary strength and protection without complex processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal reinforcing materials (expand metal, reinforcing bars) are embedded in concrete to increase rigidity, then the strength and rigidity of the floor panel are improved, but the weight of the panel increases and the production process becomes complicated
Solution Approach 1:
The patent removes metal reinforcing materials from the concrete structure entirely. Instead, it uses a foam concrete layer (specific gravity 0.4-0.8) combined with metal plates attached to the surfaces, extracting the harmful heavy metal reinforcement while maintaining structural integrity through the foam concrete's inherent properties and plate attachments.
Solution Approach 2:
The patent changes the density parameter of the concrete by using foam concrete with specific gravity 0.4-0.8, which is significantly lighter than conventional concrete. This parameter change allows the panel to achieve sufficient strength without heavy metal reinforcement, directly addressing the weight-strength contradiction.
2Strength
If metal reinforcing materials are embedded in concrete to increase rigidity, then the strength of the floor panel is improved, but the production process becomes complicated due to the need to set up materials at predetermined locations
Solution Approach 1:
The patent eliminates the complex process of embedding and positioning metal reinforcing materials within concrete. The simplified construction involves attaching metal plates to the surfaces of a foam concrete panel, which is a much simpler process that does not require setting materials at predetermined locations within the concrete matrix.
3Reliability
If steel plates are assembled into a liquid-tight hollow structure to prevent concrete leakage, then leakage prevention is achieved, but the production cost increases and the production process becomes complicated
Solution Approach 1:
The patent removes the complex liquid-tight hollow steel structure entirely. Instead, it uses a solid foam concrete panel with metal plates attached to the surfaces, which inherently prevents leakage without requiring complex assembled hollow structures. This extraction of the unnecessary complex structure directly reduces production complexity and cost.
4Length of stationary object
If the thickness of the floor panel is reduced for indoor use, then the weight and material consumption are decreased, but the strength and rigidity of the panel become insufficient
Solution Approach 1:
The patent changes the material properties by using foam concrete with specific gravity 0.4-0.8 and controlling its strength parameters. This allows the panel to maintain sufficient strength and rigidity at reduced thickness compared to conventional concrete panels, as the foam concrete's optimized properties compensate for the reduced thickness.
Solution Approach 2:
The patent creates a composite structure combining foam concrete with metal plates attached to the surfaces. This composite material approach enhances the strength-to-thickness ratio, allowing thin panels to achieve the required structural performance that would be impossible with conventional concrete alone.
5Ease of manufacture
If conventional concrete panels are produced without protective covering, then the production process is simple, but the peripheral surfaces (side surfaces and corners) are prone to damage during transport, storage, and use
Solution Approach 1:
The patent creates a composite structure where metal plates are attached to the surfaces of the foam concrete panel. These metal plates serve a dual function: they contribute to the structural strength of the panel and simultaneously protect the peripheral surfaces (side surfaces and corners) from damage during transport, storage, and use, without adding significant complexity to the production process.
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 solution results in a lightweight, durable, and easily producible floor panel with enhanced protection against damage during transport, storage, and use, while maintaining sufficient strength for flooring applications.
Implementation Method 1
a foamed cement layer comprising a porous hardened cement phase
Implementation Method 2
a fiber dispersed in the phase
Implementation Method 3
a top plate and a bottom plate which are attached to upper and lower surfaces of the foamed cement board, respectively
Data Source
AI summary
In a floor panel (10) including a foamed cement board (1) having at least a foamed cement layer (3), a top plate (5a) attached to an upper surface of the foamed cement board (1), and a bottom plate (5b) attached to a lower surface of the foamed cement board (1). The foamed cement layer (3) is configured so that the layer (3) has a porous hardened cement phase and a fiber dispersed in the phase. Also, the layer (3) has a thickness within a range from 12 to 30 mm and a specific gravity within a range from 0.8 to 1.5. Thereby, the floor panel can be light in weight while desired strengths for the floor panel are established. The floor panel can be readily produced without any complicated processes.