Integrated Rubber Concrete Barn Floor Casting
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Solution Overview
Problem
The existing methods for producing prefabricated concrete barn floor elements are labor-intensive and prone to concrete block detachment due to high loads, and concrete surfaces are slippery and degrade quickly under animal urine exposure.
Innovation Solution
A method involving a casting mold to form concrete cores with integrated rubber coverings, where the rubber coverings have openings for concrete penetration, ensuring a stable and grippy surface without the need for subsequent concrete block application, and using fresh concrete mixed with fibers for improved formability and distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If concrete blocks are separately applied and bonded to the underlying concrete beam elements, then the elastic protective elements are secured against slipping, but the manufacture becomes complex and labor-intensive
Solution Approach 1:
The patent merges the concrete core and elastic protective elements into a single integrated casting process. The elastic protective elements are placed in the mold before concrete is poured, allowing both components to be formed together as one unit, eliminating the need for separate application and bonding steps.
Solution Approach 2:
The elastic protective elements are positioned in the mold cavity before the concrete is poured. This preliminary placement ensures that the protective elements are correctly positioned and will be automatically secured when the concrete hardens around them, avoiding the need for subsequent bonding operations.
2Reliability
If concrete blocks are bonded to the underlying core structure, then the protective elements are secured, but the concrete blocks can become detached due to high loads
Solution Approach 1:
By combining the concrete core and protective elements into a single casting process, the protective elements become an integral part of the concrete structure. The concrete surrounds and locks the protective elements in place, creating a mechanically stronger connection that can withstand high loads without detachment.
3Ease of operation
If grooves are cut or milled into the concrete surface, then the grip for animals is improved, but the concrete surface ages quickly due to urine degradation
Solution Approach 1:
The patent applies a localized protective layer (elastic protective elements) on top of the concrete surface. This protective layer provides the necessary grip for animals while simultaneously protecting the underlying concrete from urine degradation, extending the service life of the concrete structure.
Solution Approach 2:
The patent creates a composite structure combining concrete (for structural strength) with elastic protective elements (for grip and urine resistance). This composite material approach allows each component to contribute its superior properties, resulting in a floor element that is both grippy and durable.
4Adaptability or versatility
If separate concrete blocks and protective elements are used, then the functional requirements are met, but the production process is labor-intensive
Solution Approach 1:
The patent combines multiple production steps into a single casting operation. The concrete core and protective elements are formed together in one process, eliminating the need for separate manufacturing and assembly steps, thereby significantly increasing production speed and reducing labor requirements.
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
This method simplifies and accelerates the production of stable barn floor elements with enhanced grip and durability, preventing concrete degradation and reducing labor costs by integrating rubber coverings directly into the concrete formation process.
Implementation Method 1
the concrete volume of the underlying concrete cores displaced by the pressing-in process penetrating into the respective openings and filling them
Data Source
Figure 1a~1b
Figure 2
Figure 3
AI summary
The invention relates to a method for manufacturing a stable floor element (100) comprising at least two longitudinal beams (120a, 120b, 120c) spaced apart from each other, wherein the method comprises: providing a mold (20) which has upwardly open casting cavities (22a, 22b, 22c) and which defines the shape of the at least two longitudinal beams (120a, 120b, 120c) spaced apart from each other; filling the open casting cavities (22a, 22b, 22c) with concrete up to a predetermined filling height to form concrete cores (122a, 122b, 122c) of the at least two longitudinal beams (120a, 120b, 120c); Applying rubber linings (124a,124b,124c) to the surface of the respective concrete cores (122a,122b,122c), each rubber lining having at least one opening (125a,125b,125c);Pressing the rubber linings (124a, 124b, 124c) laid on the surface into the respective concrete cores (122a, 122b, 122c), whereby the volume of concrete displaced by the pressing process from the underlying concrete cores (122a, 122b, 122c) penetrates and fills the respective openings (125a, 125b, 125c); removing excess concrete that emerges from the surfaces of the openings (125a, 125b, 125c); and smoothing the concrete on the surface of the openings (125a, 125b, 125c) such that a stable floor element (100) with a uniform surface is created.