Prestressed Concrete Floor Panel with Integrated Polystyrene Insulation
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Solution Overview
Problem
Existing floor construction methods are labor-intensive and time-consuming, requiring manual laying of heavy hollow blocks and formwork, and previous solutions like Filigree slabs are inflexible and require heavy equipment, while also lacking in thermal and sound insulation.
Innovation Solution
A concrete floor panel with prestressing elements and lighter materials like polystyrene concrete, injected between beams during the casting process, forming a permanent chemical bond and allowing for easy size adjustment and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If hollow blocks are manually laid and concrete topping is poured, then thermal and sound insulation are improved, but labor consumption and construction time increase significantly
Solution Approach 1:
The patent combines the structural concrete beams and the insulation material (lightweight aggregate concrete) into a single integrated casting process. The insulation material is poured into molds simultaneously with the structural concrete, eliminating the need for separate manual laying of hollow blocks and subsequent concrete topping operations, thus achieving both insulation and structural elements in one operation
Solution Approach 2:
The patent prepares pre-formed concrete beams with embedded insulation material before site installation. The insulation material is pre-positioned within the concrete beams during manufacturing, so that when beams are installed on site, the insulation is already in place, eliminating the need for time-consuming on-site assembly of insulation components
2Strength
If Filigree slabs are used, then structural integrity is improved, but flexibility and adaptability are reduced due to fixed dimensions and heavy equipment requirements
Solution Approach 1:
The patent divides the floor structure into modular concrete beams of standardized dimensions that can be easily assembled in different configurations. These segmented beams can be manufactured in standard sizes and then combined to create custom floor plans, providing both structural integrity through the beam network and flexibility in adapting to different building requirements
Solution Approach 2:
The patent uses lightweight aggregate concrete that allows for adjustment of concrete density and beam dimensions. The insulation material content can be varied to change the weight and thermal properties, enabling adaptation to different structural requirements while maintaining workability and avoiding the need for heavy equipment
3Object-affected harmful factors
If lightweight material is inserted between ribs after concrete hardening, then thermal insulation is improved, but bonding reliability deteriorates due to inability to achieve permanent bond
Solution Approach 1:
The patent incorporates the insulation material into the concrete beam structure during the initial casting process, before the concrete hardens. The lightweight aggregate concrete is poured into molds simultaneously with the structural concrete, ensuring that the insulation material is embedded within the fresh concrete matrix, achieving strong chemical bonding through the cementitious matrix while maintaining thermal insulation properties
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 reduces labor and material consumption, provides excellent thermal and sound insulation, and allows for quick assembly with reduced weight and load on foundations, while maintaining adequate load-bearing capacity.
Implementation Method 1
filled with a part of the lighter material than plain concrete combined with plain concrete within the range of the first space with a permanent chemical bond
Data Source
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AI summary
The object of the invention is a concrete floor panel consisting of a structure made of plain concrete with reinforcement sunk inside and a part of lighter material than plain concrete, characterized in that the concrete structure consists of plain concrete slab (3) where the reinforcement is in the form of prestressing elements (4), and at least two plain concrete beams (5) placed on the slab (3), wherein the beams (5) define at least one first space (6) on the slab (3), which is filled with a part of the lighter material (7) than plain concrete combined with plain concrete within the range of the first space (6) with a permanent chemical bond. The subject of the invention is also the method of obtaining a concrete floor panel and a floor made with the use of this panel.