Polymer Concrete Sandwich Segment with Foamed Plastic Core
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Solution Overview
Problem
Existing building segment technologies, such as those using polymer concrete blocks, face challenges in achieving optimal thermal insulation and resource efficiency due to thermal bridges and high material usage, which necessitate oversized structures or additional insulation measures.
Innovation Solution
A building segment design featuring two side plates made of polymer concrete with a foamed plastic core element, allowing for efficient production, reduced material usage, and improved thermal insulation through a sandwich construction that eliminates thermal bridges, along with a tongue and groove connection system for easy assembly and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If polymer concrete blocks are used for building segments, then structural strength is achieved, but thermal bridges occur and material usage increases
Solution Approach 1:
The building segment uses a composite construction with polymer concrete side plates providing structural strength and a foamed plastic core providing thermal insulation. This composite approach allows both strength and thermal insulation requirements to be met simultaneously without thermal bridges, as the foamed plastic core interrupts heat flow paths while the polymer concrete plates provide the necessary structural framework.
2Strength
If polymer concrete blocks are used for building segments, then structural strength is achieved, but material consumption increases
Solution Approach 1:
The building segment is segmented into distinct functional components: thin polymer concrete side plates for structural strength and a foamed plastic core for insulation and volume. This segmentation allows each material to be used only where needed, reducing overall polymer concrete consumption while maintaining structural integrity through the plate-core-plate configuration.
3Adaptability or versatility
If complex shapes with contours and recesses are used in polymer concrete panels, then functional requirements are met, but production time increases
Solution Approach 1:
The design segments complex functional requirements into the simple side plates and the modular foamed plastic core. The side plates maintain simple geometric forms that are easy to cast, while functional complexity is achieved through the assembly of multiple segments and the integration of the core element, which can be standardized and pre-formed.
Solution Approach 2:
The foamed plastic core acts as an intermediary element that provides insulation and structural support between the side plates, enabling functional requirements to be met without complicating the side plate geometry. The core can be customized in shape and size to accommodate different functional needs while the side plates remain simple casting forms.
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 provides enhanced thermal insulation with a low U-value, reduced material consumption, and cost-effective production, enabling efficient and resource-friendly construction with improved static properties and ease of assembly.
Implementation Method 1
between which a core element made of a foamed plastic is arranged
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Segment (1), in particular a wall segment, for a structure (18), wherein the segment comprises two side plates (2) made of polymer concrete, between which a core element (3) made of a foamed plastic is arranged, wherein the core element (3) is positively, materially and/or force-fit connected to the respective side plate (2) and has at least one through-opening (10) extending in the vertical direction (H). Furthermore, there is also a method for manufacturing the segment (1), a corner segment (15), a method for manufacturing the corner segment (15), a structure (18) and a method for manufacturing the structure (18).