Foamed Panel with Metal Support for Pool Construction
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Solution Overview
Problem
Existing methods for constructing swimming pools using foamed material panels are labor-intensive and costly due to the need for numerous blocks, extensive on-site concrete filling, and limited factory preparation capabilities, primarily because of the low mechanical strength of foamed materials.
Innovation Solution
A prefabricated self-supporting module comprising a foamed material matrix coupled with a metal supporting structure, which eliminates the need for additional concrete reinforcement and allows for larger panel sizes, enabling extensive factory preparation, including installation of electrical and hydraulic accessories, reducing on-site work significantly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If foamed material panels are used for swimming pool walls, then weight is reduced and handling is easier, but mechanical strength becomes insufficient
Solution Approach 1:
The patent combines foamed material panels with metal reinforcement elements (steel profiles, channels, or grids) embedded within the foam structure. This composite construction maintains the low weight advantage of foamed material while the metal components provide the necessary mechanical strength and structural rigidity for load-bearing walls.
2Loss of substance
If hollow foamed blocks are stacked to form formwork, then material usage is optimized, but positioning becomes laborious and time-consuming
Solution Approach 1:
The patent divides the wall structure into standardized modular panels with consistent dimensions and embedded metal reinforcement patterns. These pre-segmented panels can be quickly assembled like LEGO blocks, eliminating the need for complex on-site positioning and alignment of individual hollow blocks.
Solution Approach 2:
The metal reinforcement elements are pre-embedded in the foamed panels during factory production. This preliminary action eliminates the need for on-site reinforcement installation and concrete pouring, reducing both labor time and the amount of concrete required for joint filling.
3Productivity
If panels are made larger to reduce component数量, then assembly speed increases, but risk of breakage increases due to low structural strength
Solution Approach 1:
By embedding metal reinforcement profiles within the foamed material, the panels gain enhanced structural strength and rigidity. This allows the production of larger-format panels that maintain adequate strength-to-size ratios, reducing the total number of panels required while minimizing breakage risk during handling and installation.
Solution Approach 2:
The metal reinforcement is strategically positioned within the foamed panels at locations subject to highest stress concentrations. This localized strengthening approach optimizes the structural performance of large panels without requiring uniform thickness increases, enabling safer production of oversized components.
Data Source
AI summary
A prefabricated self-supporting module for making building structures, more particularly swimming pools, is provided. The module comprises a matrix made of foamed material and a supporting structure made of metal coupled to the matrix. The supporting structure made of metal may be embedded in the matrix made of foamed material (internal supporting structure) and/or cover the matrix made of foamed material (external supporting structure). Thanks to the provision of the supporting structure made of metal, the module is self-supporting, and it does not need any further reinforcements of reinforced concrete. Thanks to the provision of the supporting structure made of metal, the module can be used for making structural supporting elements such as floors, side walls, and so on. This module can be completely made and finished in the factory, so that the steps to be carried out on the construction site are extremely limited, with consequent economic saving.