Precast Element Integrating Structural Concrete with Thermal Insulation
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Solution Overview
Problem
Existing precast reinforced concrete elements require subsequent treatments such as plastering, insulation, and finishing to create a comfortable environment, which are time-consuming, costly, and aesthetically unsatisfactory, and do not meet stringent safety and anti-seismic standards.
Innovation Solution
A precast element comprising a structural portion with electro-welded steel reinforcements and a coating layer made of fibrous gypsum, integrated with a heat insulating layer and fiberglass connecting elements, allowing for on-site filling and equipping with electrical systems, eliminating the need for further finishing and ensuring high quality and seismic resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If disposable reinforced concrete formwork technique is used to create double-sheet elements, then structural strength is improved, but subsequent treatments (plastering, insulation, finishing) are required which increase time, cost, and reduce aesthetic quality
Solution Approach 1:
The patent merges multiple functions (structural support, thermal insulation, acoustic insulation, and aesthetic finishing) into a single integrated precast element. The double-sheet concrete structure is combined with insulation materials and coating layers during manufacturing, eliminating the need for separate subsequent treatment steps and reducing installation time.
Solution Approach 2:
The patent applies preliminary action by pre-installing insulation layers, coating layers, and even electrical systems during the precasting manufacturing process. This allows the element to be delivered ready-for-use, eliminating on-site plastering, insulation installation, and finishing work that would otherwise be required.
2Strength
If disposable reinforced concrete formwork technique is used to create double-sheet elements, then structural strength is improved, but subsequent treatments increase material and manpower costs
Solution Approach 1:
The patent combines multiple construction functions into a single precast element manufactured using disposable formwork. By integrating insulation, coating, and structural components in one manufacturing process, it eliminates the need for multiple separate construction steps, reducing overall material and labor costs despite the specialized manufacturing process.
3Strength
If disposable reinforced concrete formwork technique is used to create double-sheet elements, then structural strength is improved, but aesthetic quality and comfort are reduced due to requirement of subsequent coatings
Solution Approach 1:
The patent applies preliminary action by pre-installing aesthetic coating layers (such as gypsum or decorative finishes) during the precasting manufacturing process. This allows the element to be delivered with high aesthetic quality already achieved, eliminating on-site plastering and finishing work that would otherwise be required to achieve acceptable aesthetic results.
4Ease of operation
If subsequent treatments (plastering, insulation, finishing) are applied to reinforced concrete walls, then comfort and aesthetics are improved, but the treatments are susceptible to wear and detachment
Solution Approach 1:
The patent merges the coating layer and insulation layer with the structural concrete element into a single integrated precast unit. All layers are cured together under controlled factory conditions, creating strong bonds between materials that prevent the wear and detachment issues associated with on-site applied coatings.
Solution Approach 2:
The patent applies preliminary action by pre-installing and pre-curing all coating and insulation layers in the controlled factory environment before delivery. This ensures optimal bonding conditions and material performance are achieved under controlled conditions, preventing the wear and detachment problems that occur with on-site applications.
5Ease of operation
If subsequent treatments are applied to create comfortable environment, then thermal and acoustic insulation are improved, but additional material and manpower are required
Solution Approach 1:
The patent merges thermal insulation, acoustic insulation, and aesthetic coating functions into a single integrated precast element. By combining these functions in one manufacturing process, it eliminates the need for separate materials and applications for each function, reducing overall material quantity and simplifying the construction 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 enables the construction of ready-to-live residential and industrial buildings that are aesthetically pleasing, thermally and acoustically insulated, and meet stringent safety and anti-seismic criteria without additional finishing steps, reducing installation time and costs while maintaining high quality standards.
Implementation Method 1
both in reinforced concrete, separated from each other to form an inter-space. The double-sheet wall is provided with an iron trellis, welded to the reinforcements of both walls and adapted to make the walls themselves integral.
Implementation Method 2
a heat insulating layer (11) interposed between the coating layer (10) and the first structural layer (3)
Implementation Method 3
a coating layer (10) adapted to be exposed in the environment. The coating layer (10) comprises a coating binding material, hereinafter referred to as the 'first binding material'. The first binding material comprises gypsum.
Data Source
Figure 1
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AI summary
The precast element (1) for buildings comprises: - a structural portion (2) having a first structural layer (3) and a second structural layer (4) substantially parallel to one another and comprises a first reinforcement (5) and a second reinforcement (6) respectively, connected to one another to make the first structural layer (3) integral to the second structural layer (4); and comprises a coating portion (9) coupled to said first structural layer (3) and comprising: - a coating layer (10) adapted to be exposed in the environment; - a heat insulating layer (11) interposed between the coating layer (10) and the first structural layer (3) and defining with the heat insulating layer (11) a coating portion (9) of the element (1); and - at least one connecting element (12) which extends from the coating layer (10) to the first structural layer (3) and is partially inserted therein to retain the coating portion (9) coupled to the first structural layer (3).