Insulating Modular Elements with Internal Network for Structural Casting
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Solution Overview
Problem
Existing concrete panels lack insulation and structural strength, leading to high construction costs, complex procedures, and limitations in usage for ceilings, as they require additional manual labor and excessive concrete consumption when attempting to insulate or create a supporting structure.
Innovation Solution
Modular elements made of insulating materials with interior network elements, such as half-joints and channels, connected to form a unitary supporting structure by casting a hardening material, using materials like polyurethane foams and specific resins, allowing for efficient heat insulation and structural integrity without concrete forming elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If concrete panels are used without insulation, then construction time is reduced, but heat insulation performance deteriorates and additional manual insulation work is required
Solution Approach 1:
The insulating material is integrated into the modular element during manufacturing, before the element is used in construction. This preliminary incorporation of insulation eliminates the need for subsequent manual insulation work and maintains construction speed while providing thermal insulation performance.
Solution Approach 2:
The modular element combines insulating material with structural components into a composite structure. This integration allows the element to provide both insulation and structural function simultaneously, resolving the contradiction between construction speed and insulation performance.
2Ease of manufacture
If insulating operations are performed at a later stage, then panel manufacturing is simplified, but construction costs increase and manual working is required
Solution Approach 1:
The insulating material is incorporated into the modular element during the manufacturing stage, before construction. This preliminary action eliminates the need for additional manual insulation work during construction, reducing labor costs and overall construction expenses while maintaining manufacturing simplicity.
3Ease of operation
If conventional panels are used for ceilings, then installation is simple, but structural strength is insufficient for large-sized ceilings
Solution Approach 1:
The ceiling is divided into multiple modular elements that can be easily installed in segments. Each module maintains installation simplicity while the interconnected network provides cumulative structural strength, enabling support for large-sized ceilings.
Solution Approach 2:
The modular element combines insulating material with reinforcing network elements (such as steel or plastic bars) to create a composite structure. This composite construction provides both installation simplicity and sufficient structural strength for ceiling applications.
4Ease of manufacture
If internal channels are positioned perpendicularly along vertical and horizontal lines, then concrete filling is enabled, but concrete consumption increases and flow problems occur
Solution Approach 1:
The channel configuration is changed from traditional perpendicular vertical and horizontal arrangements to oblique orientations. This dimensional change allows concrete to flow more smoothly through the channels, reducing concrete consumption and eliminating flow problems while maintaining filling capability.
5Strength
If a network of steel or plastic bars is introduced to increase strength, then structural strength improves, but construction complexity and manual working increase
Solution Approach 1:
The reinforcing network elements are incorporated into the modular element during manufacturing, before construction. This preliminary incorporation eliminates the need for manual installation of reinforcement bars during construction, reducing construction complexity and manual working while maintaining structural strength.
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 enables a cost-effective, simple construction process with enhanced structural strength and heat insulation, reducing construction time and concrete consumption, suitable for various building components including ceilings, while eliminating the need for manual insulation and concrete forming.
Implementation Method 1
casting a hardening material in the network achieved by connecting the modular elements
Data Source
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AI summary
The invention relates to modular elements made of insulating materials for constructions, provided with at least one network element in the interior; to a network obtained by connecting modular elements; to a supporting structure achieved by casting a hardening material in the network achieved by connecting the modular elements and joining them through the supporting structure, as well as to the process for obtaining thereof. The modular element has an interior network element made up of at least two main half-joints and optionaly it may have one or more secondary half-joints, connected through vertical and oblique channels. The network obtained by assembling the modular elements is made up of main and secondary joints, connected trough vertical, horizontal and oblique channels. The unitary supporting structure is obtained by casting a material that will be harden in the unitary network for the entire construction. The process for obtaining the construction according to the invention consists of the following: connection of modular elements and the casting of material that hardens in the network defined through the connection of modular elements and the creation of a unitary supporting structure.