Polystyrene Formwork Panel with Grid-Reinforced Mortar
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Solution Overview
Problem
Existing polystyrene panels used as permanent formwork lack sufficient strength to withstand high concrete pressures during concrete wall filling, often requiring excessive support or leading to deformation or breakage.
Innovation Solution
A building board with a polystyrene core coated on both sides with a structured mortar containing hydraulic and/or polymeric binders, carbonate or silicate fillers, and glass fiber reinforcement, featuring a grid-shaped embossing for improved contact and a thin, lightweight design to enhance compressive strength and thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If polystyrene panels are used as permanent formwork without reinforcement, then the structure remains simple and lightweight, but the panels cannot withstand high concrete pressures and may deform or break
Solution Approach 1:
The patent applies composite materials by combining polystyrene foam panels with a mortar coating that contains glass fibers and a grid reinforcement structure. This composite construction provides the necessary compressive strength to withstand high concrete pressures while maintaining the lightweight advantage of the original polystyrene panels.
Solution Approach 2:
The reinforcement structure is segmented into a grid pattern with regularly spaced elements that distribute the concrete pressure across multiple points. This segmentation allows the panel to withstand high loads without requiring complete reinforcement of the entire panel surface, thus balancing strength requirements with structural simplicity.
2Strength
If a mortar coating with fibers is applied to the polystyrene board, then some reinforcement is provided, but the tensile strength does not improve significantly because fibers are not networked
Solution Approach 1:
The patent uses a composite mortar coating that combines glass fibers with a grid reinforcement structure. The grid provides the necessary tensile strength through its networked configuration, while the glass fibers enhance the mortar's overall strength and durability. This composite approach significantly improves tensile strength compared to fiber-only reinforcement.
Solution Approach 2:
The grid reinforcement is strategically positioned at critical locations where tensile stresses are most likely to occur. This localized reinforcement approach provides maximum tensile strength improvement in the most needed areas without requiring complete coverage, thus simplifying the manufacturing process.
3Strength
If the mortar layer is made thicker to improve reinforcement, then the board can withstand higher concrete pressures, but the weight of the building board increases
Solution Approach 1:
The patent uses a composite reinforcement system combining a thin mortar coating with glass fibers and a grid structure. This multi-component composite provides high compressive strength without requiring a thick mortar layer, thus maintaining the lightweight characteristic of the building board while achieving the necessary strength to withstand concrete pressures.
Solution Approach 2:
The reinforcement function is segmented across multiple components: the grid structure provides primary load-bearing capacity, the glass fibers enhance the mortar's strength, and the thin mortar coating binds these elements together. This segmentation allows achieving high strength with minimal material thickness, reducing overall weight.
4Stability of the object's composition
If additional support elements are added to withstand concrete pressure, then the panel stability improves, but the device complexity and installation effort increase
Solution Approach 1:
The patent incorporates a grid reinforcement structure within the mortar coating that provides internal stabilization. This internal grid network distributes concrete pressures evenly across the panel, enhancing stability without requiring external support elements, thus maintaining simplicity in the overall device structure.
Solution Approach 2:
The grid reinforcement and glass fiber-containing mortar coating are applied to the polystyrene panel before concrete pouring. This preliminary reinforcement structure is designed to anticipate and cushion against the high concrete pressures that will be applied during construction, preventing panel deformation or failure without requiring additional support during the concrete filling process.
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 significantly increases the board's ability to absorb compressive forces without deformation, allowing for effective use as permanent formwork with reduced weight and improved handling, while maintaining thermal insulation and structural integrity.
Implementation Method 1
a hydraulic and/or polymeric binder
Implementation Method 2
A reinforcement in the form of a glass fiber fabric is arranged on the mortar coating
Implementation Method 3
serves as thermal insulation after the concrete wall has been completed
Data Source
Figure 1~3
Figure 4
AI summary
The building panel (1) comprises a plate body made of polystyrene with a mortar coating (4) comprising a hydraulic or polymeric binder, carbonate or silicate fillers and super plasticizer on both plate sides. The carbonate or silicate is formed from fine sand. The mortar coating has a reinforcement in the form of a fiber web (5), where the side surfaces are designed with polystyrene plate (2) for carrying the mortar coating. A structure is provided on the polystyrene plate for depressions or projections (3), preferably in the form of grid-like arranged recesses or projections.