Raised Floor Element with Embedded Polymer Mesh
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Solution Overview
Problem
Existing construction materials like ceramic and glass used in raised access floors face issues with weight increase and material consumption when thickened for mechanical support, leading to handling difficulties and high transport costs, while existing reinforcement methods either fail to adequately address breakage and deflection problems or result in excessive weight and thickness.
Innovation Solution
A construction element featuring a polymer matrix with an embedded mesh of cut threads, where the mesh is completely embedded within the polymer matrix, reducing the overall weight and thickness, and optionally including an insulating layer for fire protection and enhanced mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of ceramic or glass plates is increased to avoid breakage and deflection in raised access floors, then the mechanical strength and stability are improved, but the weight increases significantly and handling becomes difficult
Solution Approach 1:
The invention applies composite materials by combining ceramic or glass plates with a polymer matrix containing an embedded mesh structure. This composite construction provides the necessary mechanical strength and deflection resistance while maintaining a reduced thickness and weight compared to solid thick plates, thus resolving the contradiction between strength and weight.
Solution Approach 2:
The invention applies local quality by concentrating reinforcement only where needed - the polymer matrix with embedded mesh is applied to the back of the plate at specific locations rather than uniformly thickening the entire plate. This localized reinforcement provides adequate mechanical strength while minimizing weight increase.
2Strength
If the thickness of plates is increased to support loads and prevent deflection, then the mechanical performance is improved, but the material consumption and transport costs increase
Solution Approach 1:
The composite structure of ceramic/glass plate combined with polymer matrix and embedded mesh provides high load-bearing capacity with minimal material consumption. The mesh structure within the polymer matrix efficiently distributes loads, allowing the use of thinner plates that consume less material while maintaining required strength.
Solution Approach 2:
The invention changes the structural parameters by introducing a mesh pattern within the polymer matrix, which optimizes the strength-to-material-ratio. This parameter change allows achieving the required load-bearing capacity with significantly reduced material consumption compared to solid thick plates.
3Strength
If existing reinforcement methods such as calcium sulphate or chipboard panels are used, then the strength is improved, but the weight and thickness increase excessively
Solution Approach 1:
The invention uses a thin polymer matrix film with an embedded mesh structure as the reinforcement layer. This thin-film approach provides adequate mechanical strength while maintaining minimal thickness, unlike bulk materials such as calcium sulphate or chipboard panels that require significant thickness to achieve comparable strength.
Solution Approach 2:
The combination of polymer matrix and embedded mesh creates a high-strength composite material that achieves the required mechanical performance in a thin profile. This composite structure is more efficient than traditional reinforcement materials, providing equivalent or superior strength with reduced thickness.
4Ease of manufacture
If the mesh is not completely embedded in the polymer matrix, then the manufacturing process is simpler, but the mechanical properties and breakage resistance are insufficient
Solution Approach 1:
The mesh is pre-positioned and completely embedded within the polymer matrix before the final curing process. This preliminary embedding action ensures optimal mechanical properties and breakage resistance while maintaining manufacturing efficiency, as the complete embedding is achieved in a single process step rather than requiring multiple operations.
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 material consumption and handling difficulties, achieves high mechanical performance with reduced weight, and meets stringent standards for static load resistance and impact strength, while allowing for thinner and lighter construction elements suitable for both indoor and outdoor raised access floors.
Implementation Method 1
a polymer matrix based on hardened resins, in which a mesh of cut threads is embedded that, being arranged on one of the sides of the rigid material, enhances the mechanical properties of the rigid material
Data Source
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Figure 3~4
AI summary
Construction element for raised floors and the like and manufacturing method thereof, which relates to a construction element for both indoor and outdoor raised floors and the like, characterized in that it is made up of a rigid component reinforced by a polymeric matrix composed of a resin, in a percentage by weight comprised between 80 and 95 % of the total weight, combined with a catalyst, the percentage by weight of which being between 5 and 20 % of the total weight, which has a filament fiber mesh completely embedded within, the proportion by weight of the embedded mesh being less than 50 % relative to the assembly formed by the polymeric matrix plus mesh, and a method for the manufacture thereof. A method for the manufacture of said element is also described.