Heated floor and ceiling panel with a corrugated layer for modular use in buildings
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Solution Overview
Problem
Conventional construction methods in building sites are time-consuming, prone to waste, and result in installation imperfections and cost overruns, as each unit is measured and installed individually, leading to inefficiencies in linear sequences of trades like carpentry, electrical work, and plumbing.
Innovation Solution
The introduction of pre-assembled floor and ceiling panels, comprising a plurality of joists, a corrugated form deck, a ceiling substrate, and an in-floor radiant heat member, which can include sound dampeners, thermal insulation, and plumbing or electrical wiring, allowing for off-site assembly and efficient on-site installation, reducing waste and improving precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional construction methods are used with linear sequence of trades, then each trade can perform its specialized function, but the construction process becomes time-consuming and inefficient
Solution Approach 1:
The patent applies preliminary action by pre-assembling floor and ceiling panels in a factory setting before transporting them to the construction site. The panels are manufactured with integrated components including joists, subflooring, ceiling materials, insulation, and utility conduits already in place, eliminating the need for sequential on-site installation by different trades and dramatically reducing construction time.
Solution Approach 2:
The patent merges multiple separate construction elements into a single integrated panel assembly. The floor panel combines structural joists, subflooring, ceiling substrate, thermal insulation, sound dampeners, and utility pathways into one unified component that can be installed as a single unit, thereby improving productivity by eliminating repetitive measurement, cutting, and installation steps.
2Loss of substance
If conventional field construction is used with individual unit installation, then flexibility in on-site adjustments is maintained, but waste and installation imperfections increase
Solution Approach 1:
By performing all cutting, fitting, and assembly operations in the controlled factory environment before shipment, the patent eliminates on-site material waste from incorrect measurements or cutting errors. Precise manufacturing equipment and quality control processes ensure high precision installation without the need for field adjustments or rework.
Solution Approach 2:
The patent uses digital modeling and manufacturing techniques to create precise replicas of the designed floor and ceiling panels. Computer-aided manufacturing ensures that each panel is produced with exact dimensions and specifications, eliminating the variability and imprecision associated with manual field construction and reducing material waste from errors.
3Productivity
If modular construction with off-site assembly is used, then construction speed and precision are improved, but the complexity of integrating multiple components increases
Solution Approach 1:
The patent combines multiple functional components into a single integrated floor panel assembly that includes structural elements (joists), finishing materials (subflooring and ceiling substrate), thermal and acoustic insulation, and utility pathways. This merging reduces on-site installation complexity by delivering a complete, pre-integrated unit that requires minimal assembly compared to installing separate components individually.
Solution Approach 2:
The floor panel is designed as a universal assembly that simultaneously provides structural support, thermal insulation, sound dampening, and utility routing capabilities. The standardized panel design with integrated features allows it to serve multiple functions in a single installation, reducing the overall complexity of the building system compared to separate installations of each function.
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
This approach streamlines construction by enabling faster, more precise installation of building components, reducing waste and costs, while enhancing sound insulation and heating efficiency through integrated radiant heat systems.
Implementation Method 1
an in-floor radiant heat member disposed between the corrugated form deck and the ceiling substrate
Implementation Method 2
thermal insulation disposed between the corrugated form deck and the ceiling substrate
Implementation Method 3
a sound dampener disposed between the corrugated form deck and the plurality of joists
Data Source
AI summary
Floor and ceiling panels and methods of constructing a floor system for a building are described. In some embodiments, a panel includes a plurality of joists, a corrugated form deck disposed above and attached to the plurality of joists, a ceiling substrate disposed below and attached to the plurality of joists, and an in-floor radiant heat member disposed between the corrugated form deck and the ceiling substrate. In some embodiments, the panel includes a plurality of joists, a corrugated form deck disposed above and attached to the plurality of joists, and a sound dampener disposed between the corrugated form deck and the plurality of joists. In some embodiments, the method includes attaching a pre-assembled panel to a frame of the building and pouring concrete onto the panel so that a radiant heat member is separated from the concrete by a corrugated form deck of the panel.