HIGH-PERFORMANCE COMPOSITE CONCRETE PANELS FOR ENHANCED THERMAL EFFICIENCY AND MECHANICAL STABILITY IN COST-EFFECTIVE ROOM HEATING APPLICATION

Abstract

The present invention relates to composite concrete panels developed as a sustainable alternative to conventional limestone panels in heating systems, particularly for hammams in cold regions like Kashmir. These panels, comprising high alumina cement, limestone aggregates, sand, polypropylene fibers, and water, offer superior thermal efficiency, durability, and cost-effectiveness. They heat faster, retain heat longer, and resist spalling under high temperatures while ensuring structural integrity with minimal reductions in compressive and tensile strength. Compared to limestone panels, the composite panels lower material costs by up to 75% and eliminate the environmental impact of limestone mining, thus preserving natural habitats. The invention also outlines methods for constructing efficient heating systems with uniform thermal distribution. Applications include insulated flooring, industrial heating, and energy-efficient construction materials. Validated through thermal and mechanical testing, these panels demonstrate superior performance, making them an economical and environmentally friendly solution for modern heating systems.

Specification

Description:FIELD OF INVENTION
[0001] The present invention relates to the field of construction materials and thermal systems, specifically to composite concrete panels designed for use in heating applications such as traditional hammams or similar thermal systems. Hammams are traditionally used for room heating in cold regions such as Kashmir and feature an underfloor heating system where heat is generated below the flooring and radiated into the room. More particularly, the invention focuses on composite panels that exhibit enhanced thermal efficiency, mechanical stability, and cost-effectiveness, offering a sustainable alternative to conventional limestone panels typically used in such systems. The invention addresses the need for improved heat retention and durability under high-temperature conditions while reducing the environmental impact associated with the mining and processing of limestone. By optimizing the thermal and mechanical properties of the panels, the invention also enhances the operational efficiency and affordability of traditional heating systems.

BACKGROUND OF INVENTION
[0002] Heating systems, such as traditional hammams, have been widely utilized in cold regions to provide warmth and comfort during harsh winters. Hammams are especially common in areas like Kashmir, where sub-zero temperatures prevail for several months each year. These systems typically feature an underfloor heating mechanism, where heat generated below the flooring radiates into the room, ensuring consistent warmth. Conventional hammams employ limestone panels for heat retention, relying on their thermal properties to maintain elevated temperatures. However, the use of limestone panels presents several limitations, including high costs, susceptibility to thermal degradation, and significant environmental impacts associated with limestone mining and processing.
[0003] Concrete has been explored as a potential alternative to limestone due to its availability and structural properties. However, traditional concrete materials often exhibit poor performance under elevated temperatures, including reduced compressive strength, spalling, and increased thermal conductivity. These deficiencies limit the suitability of conventional concrete for heating applications such as hammams.
[0004] In light of these challenges, there is a need for a cost-effective, thermally efficient, and mechanically robust material that can replace limestone in heating applications. The present invention addresses this need by introducing composite concrete panels composed of high alumina cement, limestone aggregates, polypropylene fibers, sand, and water. These panels demonstrate superior thermal efficiency, enhanced mechanical stability, and environmental sustainability, making them ideal for traditional hammams and other heating systems. Furthermore, these panels provide faster heating, better heat retention, and a significant reduction in construction costs compared to conventional limestone panels, contributing to a more sustainable and economical solution for heating applications.
SUMMARY OF INVENTION
[0005] The present invention provides a novel composite concrete panel designed to serve as an alternative to traditional limestone panels in heating systems, particularly in hammams commonly used in cold regions like Kashmir. Hammams, which rely on an underfloor heating mechanism to radiate warmth into rooms, have traditionally employed limestone panels for their thermal properties. However, the high costs, thermal degradation, and environmental impact associated with limestone necessitate a more efficient and sustainable alternative.
[0006] The composite panels of the present invention are constructed using a unique formulation that includes high alumina cement, limestone aggregates, sand, polypropylene fibers, and water. This combination imparts the panels with enhanced thermal and mechanical properties, making them efficient and cost-effective for heating applications. The panels exhibit a higher specific heat capacity compared to limestone, enabling faster heating and extended heat retention. They are resistant to spalling and exhibit controlled reductions in compressive and tensile strength at elevated temperatures, ensuring durability under thermal stress. These attributes make the panels suitable for sustained use in high-temperature environments, such as hammams.
[0007] In addition to superior performance, the composite panels offer significant economic benefits. The material costs of the composite panels are up to 75% lower than those of limestone panels. Moreover, the panels mitigate the environmental impact associated with limestone mining and processing, promoting sustainable construction practices.
[0008] The invention encompasses the material composition, preparation methods, and application of the composite concrete panels in various heating systems. It also includes methods for testing and optimizing the thermal and mechanical properties of the panels for specific use cases, ensuring adaptability and reliability in a wide range of thermal applications.
PRIOR ART OF INVENTION
[0009] Traditional heating systems, such as hammams, have relied extensively on limestone panels for heat retention and distribution. Limestone's thermal properties, including its ability to retain heat for extended periods, have made it a preferred material in these applications. However, the use of limestone panels presents several limitations. These include high material costs, susceptibility to thermal degradation such as spalling and cracking, and significant environmental impacts associated with limestone mining and processing. The extraction of limestone often involves large-scale stone quarrying, which disrupts natural ecosystems, causes habitat destruction, and contributes to environmental degradation.
[0010] Concrete has been explored as a potential alternative due to its availability and structural properties. However, traditional concrete often fails to perform adequately under elevated temperatures, suffering from reduced compressive strength, increased thermal conductivity, and spalling under thermal stress. These limitations restrict its application in systems requiring prolonged heat retention and resistance to high temperatures.
[0011] In light of these challenges, there exists a critical need for a cost-effective, thermally efficient, and environmentally sustainable material that can replace limestone in heating applications. The present invention addresses this need by introducing composite concrete panels composed of high alumina cement, limestone aggregates, polypropylene fibers, sand, and water. These panels not only demonstrate superior thermal efficiency and mechanical stability but also significantly reduce reliance on stone quarrying, thereby promoting environmental sustainability. By preventing the extensive cutting of mountains for limestone, the invention helps mitigate habitat destruction and reduces the ecological footprint of construction activities. Furthermore, the material costs of the composite panels are up to 75% lower than those of limestone panels, making them an ideal solution for both traditional and modern heating systems.
[0012] This environmentally conscious and technically advanced solution overcomes the limitations of prior art, setting a new benchmark for sustainable heating materials in construction.
[0013] The present invention offers several distinct advantages over conventional limestone panels and prior attempts at using concrete in heating systems, particularly for applications such as hammams. These advantages include:
[0014] Enhanced Thermal Efficiency: The composite concrete panels exhibit a higher specific heat capacity (658.655 J/kg°C), enabling faster heating and prolonged heat retention compared to limestone panels. This reduces energy consumption and improves the overall efficiency of heating systems.
[0015] Superior Mechanical Stability: The panels demonstrate controlled reductions in compressive and tensile strength at elevated temperatures, maintaining structural integrity and resisting spalling. Polypropylene fibers mitigate internal stresses caused by thermal expansion, ensuring durability in high-temperature environments.
[0016] Environmental Sustainability: By replacing limestone panels, which rely on extensive mountain quarrying, the invention significantly reduces environmental degradation associated with stone mining. This prevents habitat destruction, minimizes ecological disruption, and promotes sustainable construction practices.
[0017] Cost-Effectiveness: The material costs of the composite panels are up to 75% lower than those of limestone panels.
[0018] Resistance to Thermal Degradation: The panels exhibit superior performance under elevated temperatures, including resistance to spalling and cracking, which are common issues with both limestone and traditional concrete materials.
[0019] Energy Efficiency: Faster heating times reduce the duration and amount of fuel required for heating systems, further lowering operational costs and environmental emissions.
[0020] Uniform Heat Distribution: The composite panels ensure consistent temperature profiles across their surfaces, eliminating cold spots and improving user comfort in applications like hammams and heated flooring.
[0021] Scalability and Adaptability: The panels can be easily fabricated using standard concrete production techniques and locally available materials, making them scalable and adaptable for various applications, including insulated flooring, industrial heating systems, and thermal storage.
[0022] Longevity and Reduced Maintenance: With improved mechanical and thermal stability, the panels require less frequent replacement or maintenance, reducing long-term costs and environmental waste.
[0023] Alignment with Green Building Practices: By reducing reliance on quarried limestone and offering a sustainable alternative, the invention supports environmentally friendly building practices and contributes to global efforts to lower the carbon footprint of construction activities.
BRIEF DESCRIPTION OF DRAWINGS
[0024] The accompanying drawings illustrate the embodiments of systems, methods, and other aspects of the disclosure. Any person with ordinary skills in the art will appreciate that the illustrated element boundaries (e.g., boxes, groups of boxes, or other shapes) in the figures represent an example of the boundaries. In some examples, one element may be designed as multiple elements, or multiple elements may be designed as one element. In some examples, an element shown as an internal component of one element may be implemented as an external component in another and vice versa. Furthermore, the elements may not be drawn to scale.
[0025] Various embodiments will hereinafter be described in accordance with the appended drawings, which are provided to illustrate, not limit, the scope, wherein similar designations denote similar elements, and in which:
[0026] Figure 1 illustrates a cross-sectional view of a conventional hammam construction. The structure comprises brick walls forming the enclosure, with 9" × 9" brick columns providing vertical support for the flooring system. The flooring includes a layer of limestone tiles, approximately 4 inches thick, positioned above a 2-inch layer of vermiculite for insulation. Below the flooring, a sand layer is placed over the concrete foundation, serving as a thermal buffer to retain and gradually release heat. This configuration represents the traditional design and material composition of a hammam, highlighting the reliance on limestone tiles for thermal performance and structural integrity.
[0027] Figure 2 illustrates the results of a heat retention test comparing the thermal performance of conventional limestone stone panels and composite concrete panels. The graph plots temperature (°C) against time (minutes) for the upper and lower surfaces of both panel types. The results demonstrate that composite concrete panels heat up more quickly and achieve higher peak temperatures compared to limestone panels, while maintaining comparable cooling rates. The data highlights the superior thermal performance of composite concrete panels, with faster heat absorption and effective heat retention over time.
[0028] Figure 3 depicts the rise and fall in temperature over time for both the lower and upper surfaces of limestone stone panels and composite concrete panels. The graph shows temperature (°C) plotted against time (minutes), highlighting the thermal behavior of each material. The composite concrete panels demonstrate faster heating rates and reach higher peak temperatures compared to limestone stone panels. The cooling rates of both materials are similar, with composite panels exhibiting slightly improved heat retention at elevated temperatures. This figure underscores the thermal efficiency of the composite panels, reinforcing their suitability for heating applications.
DETAILED DESCRIPTION OF INVENTION
[0029] The present disclosure is best understood with reference to the detailed figures and description set forth herein. Various embodiments have been discussed with reference to the figures. However, those skilled in the art will readily appreciate that the detailed descriptions provided herein with respect to the figures are merely for explanatory purposes, as the methods and devices may extend beyond the described embodiments. For instance, the teachings presented and the needs of a particular application may yield multiple alternative and suitable approaches to implement the functionality of any detail described herein. Therefore, any approach may extend beyond certain implementation choices in the following embodiments.
[0030] References to "one embodiment," "at least one embodiment," "an embodiment," "one example," "an example," "for example," and so on indicate that the embodiment(s) or example(s) may include a particular feature, structure, characteristic, property, element, or limitation but that not every embodiment or example necessarily includes that particular feature, structure, characteristic, property, element, or limitation. Further, repeated use of the phrase "in an embodiment" does not necessarily refer to the same embodiment.
[0031] Methods of the present invention may be implemented by performing or completing manually, automatically, or a combination thereof, selected steps or tasks. The term "method" refers to manners, means, techniques, and procedures for accomplishing a given task including, but not limited to, those manners, means, techniques, and procedures either known to or readily developed from known manners, means, techniques, and procedures by practitioners of the art to which the invention belongs. The descriptions, examples, methods, and materials presented in the claims and the specification are not to be constructed as limiting but rather as illustrative only. Those skilled in the art will envision many other possible variations within the scope of the technology described herein.
[0032] The present invention pertains to composite concrete panels that serve as an innovative alternative to traditional limestone stone panels in heating systems, such as hammams. These panels are characterized by their enhanced thermal efficiency, mechanical stability, and cost-effectiveness, addressing the inherent limitations of limestone panels, including high costs, thermal degradation, and environmental concerns. The composite panels are composed of a unique mixture of high alumina cement, limestone aggregates, sand, polypropylene fibers, and water. High alumina cement serves as a binder, offering quick-setting properties and superior performance at elevated temperatures. Limestone aggregates provide structural stability, while polypropylene fibers mitigate spalling under thermal stress by forming voids during heating, reducing internal pressure buildup, and enhancing tensile strength. Sand and water contribute to the consistency of the concrete mix, facilitating uniform heat distribution.
[0033] As illustrated in Figure 1, a conventional hammam structure employs limestone panels supported by brick columns and a sand layer that acts as a thermal buffer. The present invention replaces these limestone panels with composite concrete panels, which not only heat up more efficiently but also retain heat for extended periods. The panels' enhanced thermal performance is demonstrated in Figures 2 and 3. Figure 2 illustrates the results of heat retention tests, showing that the composite panels reach higher peak temperatures and heat up faster than limestone panels while maintaining similar cooling rates. Figure 3 further highlights the rapid heat absorption of the composite panels, which reach a peak temperature of approximately 500°C on the lower surface, outperforming limestone panels in terms of thermal conductivity and specific heat capacity.
[0034] The mechanical performance of the composite panels is also superior to that of traditional materials. The panels exhibit controlled reductions in compressive strength at elevated temperatures, maintaining structural integrity even at 600°C. Additionally, the incorporation of polypropylene fibers enhances tensile strength, preventing cracking under thermal stress and ensuring durability during prolonged use. These panels were tested in a prototype hammam, as shown in Figure 1, where compressive strength and heat retention tests validated their performance. The prototype demonstrated that the panels maintained strength over time while providing effective heat retention, confirming their suitability for high-temperature applications.
[0035] Moreover, the composite panels are significantly more economical than limestone panels. The material costs of the composite panels are up to 75% lower than those of limestone panels, resulting in substantial construction cost reductions. The invention also contributes to environmental sustainability by reducing reliance on limestone mining, which is associated with environmental degradation. This invention, with its superior thermal and mechanical properties, cost-effectiveness, and environmental benefits, provides a transformative solution for traditional hammam systems and other thermal applications, such as insulated flooring and industrial heating systems.
[0036] This detailed description emphasizes the composite concrete panels' innovative composition, thermal and mechanical advantages, and practical applications, distinguishing them as a significant advancement over prior art in the field of heating systems.
[0037] Figure 1 illustrates a cross-sectional view of a traditional hammam structure, highlighting the arrangement of its primary components. The construction features brick walls as the enclosure, which provide structural support and insulation. Within the structure, 9" × 9" brick columns are evenly distributed, serving as load-bearing elements to support the flooring system. Positioned atop the brick columns are layers of materials designed for heat retention and distribution.
[0038] The flooring system consists of a 4-inch-thick layer of limestone tiles, traditionally used for their thermal properties and ability to retain heat for extended periods. Beneath the limestone tiles, a 2-inch vermiculite insulation layer is provided to minimize heat loss and enhance the overall thermal efficiency of the hammam. Below this insulation layer lies a sand layer, which acts as a thermal buffer by absorbing and gradually releasing heat, ensuring even heat distribution across the structure. This sand layer rests on a concrete floor, which forms the foundation of the structure, providing stability and strength.
[0039] The configuration shown in Figure 1 represents the traditional design of a hammam, demonstrating the reliance on limestone tiles for thermal performance and the use of multiple layers to optimize heat retention and structural integrity. The invention proposes the replacement of limestone tiles with composite concrete panels, which enhance the thermal efficiency, mechanical stability, and cost-effectiveness of the hammam, as described in subsequent figures and sections. Figure 1 thus serves as a foundational depiction for understanding the improvements introduced by the present invention.
[0040] Figure 2 presents the results of a heat retention test comparing the thermal performance of conventional limestone stone panels and the innovative composite concrete panels introduced in the present invention. The graph plots the temperature (°C) over time (minutes) for the upper and lower surfaces of both panel types, offering a detailed representation of their heat absorption, retention, and dissipation characteristics.
[0041] The data in Figure 2 demonstrate that the composite concrete panels achieve significantly faster heating rates compared to limestone stone panels. For the lower surface, the composite panels reach their peak temperature more rapidly, indicating improved thermal conductivity. Similarly, the upper surface of the composite panels reflects an efficient transfer of heat through the material. This rapid heat absorption reduces the time required for the heating system, such as a hammam, to reach its optimal operating temperature, enhancing energy efficiency.
[0042] Additionally, Figure 2 highlights the superior heat retention properties of the composite concrete panels. Despite heating faster, the cooling profiles of both materials are comparable, with the composite panels exhibiting similar rates of temperature decline over time. This demonstrates that the composite panels not only heat up more efficiently but also retain heat effectively, making them ideal for prolonged use in thermal applications.
[0043] The graph also illustrates the performance differences between the lower and upper surfaces of both materials, emphasizing the uniformity of heat distribution in the composite panels compared to the less efficient limestone stone panels. The enhanced thermal properties of the composite panels, attributed to their unique composition of high alumina cement, limestone aggregates, polypropylene fibers, and sand, are evident in the results depicted in Figure 2.
[0044] Figure 2 underscores the thermal advantages of the composite concrete panels, including faster heat absorption, effective heat retention, and uniform temperature distribution. These properties position the composite panels as a superior alternative to limestone stone panels in heating applications, reducing energy consumption and improving operational efficiency. This figure serves as a critical validation of the invention's thermal performance improvements over prior art.
[0045] Figure 3 illustrates the rise and fall in temperature over time for the lower and upper surfaces of both conventional limestone stone panels and the composite concrete panels developed in this invention. The graph provides a detailed comparison of the thermal behavior of each material by plotting temperature (°C) against time (minutes), thereby highlighting their performance during both heating and cooling cycles.
[0046] The graph reveals that the composite concrete panels demonstrate significantly faster heating rates compared to limestone stone panels. The lower surface of the composite panels reaches a peak temperature of approximately 500°C in a shorter time, showcasing the material's superior thermal conductivity and ability to absorb heat quickly. Similarly, the upper surface of the composite panels exhibits faster heat transfer, indicating the uniform thermal distribution within the material. In contrast, the limestone stone panels require more time to reach peak temperatures, reflecting their relatively lower thermal conductivity.
[0047] During the cooling phase, both materials exhibit similar rates of temperature decline, indicating comparable heat retention capabilities. However, the composite panels maintain slightly higher temperatures for a longer duration, emphasizing their enhanced ability to retain heat. This prolonged heat retention is particularly advantageous in heating systems, such as hammams, as it reduces the frequency of reheating and improves energy efficiency.
[0048] The graph also highlights the uniformity of temperature changes across the surfaces of the composite panels, which is attributed to their unique composition of high alumina cement, limestone aggregates, polypropylene fibers, and sand. This composition not only improves thermal efficiency but also ensures consistent performance across different layers of the panel, reducing thermal stress and potential cracking.
[0049] Figure 3 demonstrates the thermal superiority of the composite concrete panels over conventional limestone stone panels. The faster heating, uniform thermal distribution, and effective heat retention make the composite panels a highly efficient and cost-effective alternative for thermal applications. This figure serves as critical evidence of the invention's improved thermal performance, validating its suitability for use in systems requiring high thermal efficiency and stability.
[0050] The composite concrete panels described in the present invention are versatile and can be utilized in various applications requiring thermal efficiency, mechanical stability, and cost-effectiveness. The key applications include:
[0051] Hammams and Traditional Heating Systems: The panels are ideal replacements for conventional limestone stone panels in hammams, where they provide faster heating, better heat retention, and significant cost savings. They also enhance operational efficiency during cold weather conditions.
[0052] Residential and Commercial Heated Floors: Due to their high specific heat capacity and uniform heat distribution, the panels can be incorporated into residential and commercial heated flooring systems, improving energy efficiency and reducing heating costs.
[0053] Industrial Heating Systems: The panels are suitable for use in high-temperature industrial applications, such as kilns, furnaces, and thermal chambers, where they can withstand elevated temperatures without compromising structural integrity.
[0054] Energy-Efficient Building Materials: The panels can be integrated into building construction as thermal insulators or structural components, providing enhanced heat retention and reducing energy consumption in cold climates.
[0055] Insulated Flooring for Cold Storage: The panels' thermal efficiency makes them a viable option for insulated flooring in cold storage facilities, maintaining stable internal temperatures and reducing energy requirements.
[0056] Heat Retention Applications in Rural Areas: The panels offer an economical solution for rural heating applications, such as community spaces and traditional kitchens, where affordable and sustainable heating solutions are required.
[0057] Fire-Resistant Construction: With their ability to resist spalling and retain structural integrity at high temperatures, the panels can be used in fire-resistant construction for critical infrastructure, such as data centers, hospitals, and storage facilities.
[0058] Green Construction Initiatives: By reducing the reliance on limestone mining and promoting the use of sustainable materials, the panels align with environmentally conscious construction practices, contributing to lower carbon footprints.
[0059] Thermal Storage Systems: The panels can be employed in thermal energy storage systems, where their heat retention properties allow efficient storage and release of thermal energy for applications such as solar water heating.
[0060] Customized Thermal Structures: The panels can be adapted for use in specialized thermal structures, including saunas, thermal baths, and hot yoga studios, where controlled heating and insulation are critical.
[0061] These applications demonstrate the versatility and practical benefits of the composite concrete panels, highlighting their ability to address a wide range of needs across residential, commercial, and industrial sectors. The invention offers a sustainable, efficient, and cost-effective solution to various thermal and structural challenges, making it a significant advancement in construction and heating technologies.
, Claims:We Claim:
1. A composite concrete panel comprising high alumina cement, limestone aggregates, sand, polypropylene fibers, and water, wherein the panel exhibits a specific heat capacity exceeding 650 J/kg°C and is configured to replace conventional limestone stone panels in heating systems such as hammams, providing faster heat absorption and prolonged heat retention, as demonstrated in Figure 2 and Figure 3.
2. A heating system comprising:
a) a base structure with brick columns (9" × 9") supporting a sand layer;
b) composite concrete panels placed above the sand layer;
c) the composite panels configured to retain heat for an extended period and resist thermal degradation, as illustrated in Figure 1.
3. A method for constructing a thermal heating system, the method comprising:
a) Preparing composite concrete panels using high alumina cement, limestone aggregates, polypropylene fibers, sand, and water;
b) Installing said panels above an insulating layer in a heating structure;
c) Achieving faster heating and uniform thermal distribution, as demonstrated in Figure 3.
4. A composite concrete panel as claimed in claim 1, wherein the polypropylene fibers are incorporated in a range of 0.3-1.2% by weight of the concrete mix, enabling resistance to spalling at elevated temperatures, as evidenced by the spalling-free performance in Figure 2.
5. A thermal heating system comprising:
a) Composite concrete panels placed on a structural foundation;
b) Insulating layers beneath said panels configured to reduce heat loss;
wherein the system achieves uniform temperature distribution across the panels' surfaces, as depicted in Figure 3.
6. The composite concrete panel as claimed in claim 1, wherein the panel exhibits controlled compressive strength degradation of no more than 24% at 400°C and a gradual reduction in tensile strength, ensuring structural integrity at elevated temperatures.
7. The heating system as claimed in claim 2, wherein the composite panels are supported by an underlying vermiculite layer of 2 inches, further enhancing insulation, as shown in Figure 1.
8. The method as claimed in claim 3, wherein the composite concrete panels are installed in a hammam structure, providing a 75% reduction in overall construction costs compared to limestone stone panels, as detailed in Figure 1.
9. The composite concrete panel as claimed in claim 4, further comprising a surface treatment to enhance durability and abrasion resistance, ensuring suitability for high-traffic applications in heating systems.
10. The thermal heating system as claimed in claim 5, wherein the composite concrete panels are arranged in a configuration to maintain uniform heat retention for at least 12 hours, as demonstrated in Figure 2.

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