Nestable Cavity Elements for Reinforced Concrete Slabs
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Solution Overview
Problem
Existing construction elements for reinforced concrete slabs using spherical elements for cavities face high transport costs, complexity in manufacturing, difficulty in manipulation, especially in automated processes, and suboptimal embedding of top reinforcement nets due to floating issues.
Innovation Solution
The use of nestable, conical or flower pot-shaped elements with air holes and locking parts that can be easily embedded and anchored within the concrete layer, reducing the need for additional top-side anchoring and simplifying the construction process by allowing for efficient transport and automated placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If spherical elements are used for cavities, then the construction element can be manufactured, but transport costs increase due to large occupied volume
Solution Approach 1:
The patent applies nesting by placing multiple spherical cavity elements inside each other during transport. The spheres are arranged concentrically with smaller spheres inside larger ones, dramatically reducing the volume occupied during transportation while maintaining the same number of functional cavity elements. This directly resolves the contradiction between transport volume and transport costs.
2Ease of operation
If spherical elements are used for cavities, then the construction element can be manufactured, but manipulation difficulty increases especially in automated processes
Solution Approach 1:
The patent uses spherical elements whose curved geometry facilitates automated manipulation. The spherical shape allows for easy grasping by robotic grippers, random orientation without affecting function, and simple placement into molds. The curvature enables the spheres to be easily held and positioned by automated systems compared to irregularly shaped alternatives.
3Ease of manufacture
If spherical elements are used for cavities, then the construction element can be manufactured, but manufacturing complexity increases due to precise top reinforcement net placement
Solution Approach 1:
The patent employs spherical elements with self-locking features that automatically secure the top reinforcement net in place during concrete pouring. The spheres' geometry and interaction with the reinforcement net create automatic positioning and locking mechanisms, eliminating the need for precise pre-placement of the net and reducing manufacturing complexity while maintaining structural integrity.
4Reliability
If spherical elements are used for cavities, then the construction element can be manufactured, but top reinforcement net embedding quality deteriorates due to floating
Solution Approach 1:
The patent addresses the floating issue by using spherical elements with weighted bottoms or embedded anchoring features that counteract the buoyant force of liquid concrete. The counterweight mechanism ensures the spheres remain firmly positioned during concrete pouring, preventing floating and ensuring proper embedding of the top reinforcement net without requiring additional separate locking elements.
Data Source
AI summary
Construction element for forming a reinforced concrete slab (2), consisting of the combination of at least a hardened concrete layer (3), at least a number of reinforcement elements (4) and elements (5) extending at least partially from the concrete layer (3) and defining cavities (6), whereby these elements (5) are designed to be covered with concrete (7) at a later stage characterised in that the above-mentioned elements (5) defining the cavities (6) consist of elements (5) which can be mutually nested as such.