Folded Sheet Edge Protector for Concrete Slab Spalling
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Solution Overview
Problem
Existing edge protectors for concrete floor slabs are prone to failure due to insufficient depth of concrete behind the protector, leading to spalling and cracking under traffic, as the initial design's concrete thickness is inadequate for long-term stability.
Innovation Solution
A folded sheet edge protector with an upper and lower portion, where the anchor portion extends at an angle from the lower portion, increasing the concrete thickness behind the protector, and optionally including inserts or support strips to enhance stability and prevent debris entry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the upper arm is bent to head below the upper surface of the slab, then the edge protection is improved, but the depth of concrete that can be laid over the upper arm becomes too thin for long term stability
Solution Approach 1:
The patent transitions from a two-dimensional bent upper arm to a three-dimensional anchor portion that extends horizontally beneath the slab. This dimensional change allows the protector to gain purchase in the horizontal plane rather than relying solely on vertical concrete cover, solving the contradiction between protection effectiveness and concrete thickness requirements
Solution Approach 2:
The patent divides the edge protector into distinct functional segments: an upper arm for immediate protection, a vertical portion for side protection, and a separate anchor portion for stability. This segmentation allows each component to be optimized independently, with the anchor portion specifically designed to provide stability without requiring excessive concrete thickness
2Reliability
If the upper arm is bent to provide protection, then the protective function is improved, but the concrete area immediately behind the bend breaks-up easily under traffic
Solution Approach 1:
The patent extracts the anchoring function from the upper arm and places it in a separate anchor portion that extends horizontally beneath the slab. This removes the source of concrete stress concentration (the bend) from the protected area, allowing the concrete behind the upper arm to maintain its full strength without being compromised by trafficking loads
3Stability of the object's composition
If individual slabs are used to prevent cracking, then the slab integrity is improved, but exposed edges are created that are vulnerable to spalling
Solution Approach 1:
The edge protector serves multiple functions simultaneously: it protects the exposed edge from spalling, provides a template for consistent edge finishing, and maintains the integrity of the joint between slabs. This multi-functionality allows individual slabs to maintain their integrity while the collector collectively addresses the vulnerability of exposed edges
Data Source
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Figure 3A~3B
AI summary
Edge protectors are useful to be cast into the edges of concrete slabs to prevent spalling thereof after shrinkage has occurred and a gap has formed between adjacent slabs. An alternative edge protector (10) is described which comprises a first folded sheet having, in use, an upper (35) and a lower portion (25), the fold being on a first side of the first folded sheet and being alignable, in use, with the sidewall of the slab, the upper portion being planar and being arrangeable, in use, with its upper surface coplanar with the upper surface of the slab, the lower portion extending at least partially under the upper portion in a direction away from the fold, and continuing from the end of the lower portion in the same general direction, without any further folds or bends greater than 90 degrees, as an anchor portion (20) such that the anchor portion is arrangeable within the slab.