Extruded Aluminum Structural Panels with Internal Routing Channels
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Solution Overview
Problem
Existing structural panels, such as Structural Insulated Panels (SIPs), face issues with durability, corrosion resistance, difficulty in incorporating mechanical and electrical lines, inadequate fire safety, and limited building configuration options.
Innovation Solution
A multi-purpose structural panel made from extruded aluminum alloy with interior channels for insulation and ventilation, featuring male and female interlocking components, and channels for mechanical, electrical, and plumbing lines, allowing for efficient construction and integration of smart features like temperature sensing and electromagnetic insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If Structural Insulated Panels (SIPs) are used for construction, then insulation performance is improved, but durability and corrosion resistance deteriorate due to delamination in poor conditions
Solution Approach 1:
The patent employs a composite structure consisting of two metal veneers (aluminum or stainless steel) sandwiching a foam core board, creating a metal-foam-metal composite panel that combines the insulation properties of foam with the durability and corrosion resistance of metal cladding, eliminating the delamination issue of traditional SIPs
Solution Approach 2:
The patent changes the material parameters by substituting traditional wood or gypsum veneers with metal materials (aluminum or stainless steel), thereby transforming the panel's resistance to moisture, corrosion, and structural degradation while maintaining insulation performance
2Ease of operation
If SIPs are cut to run mechanical, electrical, or plumbing lines, then flexibility in routing is improved, but strength of the panel deteriorates
Solution Approach 1:
The patent segments the panel's interior by providing pre-formed channels within the foam core board that are separated by internal dividing walls, allowing mechanical, electrical, and plumbing lines to be routed through these dedicated pathways without cutting through the structural panel layers, thus preserving panel strength
Solution Approach 2:
The patent moves the routing function from a two-dimensional surface (cutting through the panel) to a three-dimensional internal space by incorporating hollow channels within the foam core, enabling line installation without compromising the panel's structural integrity
3Object-affected harmful factors
If traditional construction materials are used, then fire safety ratings are improved, but insulation performance deteriorates
Solution Approach 1:
The patent creates a composite structure where metal veneers (aluminum or stainless steel) provide fire resistance while the foam core board maintains insulation performance, achieving both fire safety ratings and thermal insulation without the trade-off present in traditional materials
4Strength
If Intermodal shipping containers are used for construction, then structural strength is improved, but adaptability in building configurations deteriorates due to limited standard sizes
Solution Approach 1:
The patent divides the building structure into modular panel units that can be assembled in various configurations, allowing adaptability in building designs while maintaining structural strength through the robust metal-foam-metal construction of each panel
Solution Approach 2:
The patent creates universal panel components that can serve multiple functions (structural support, insulation, fire protection, and routing conduits) and be configured in various building arrangements, providing both strength and adaptability unlike fixed-size shipping containers
Data Source
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AI summary
The present invention is directed to a multi-purpose panel member which may be utilized as any surface or support beam in a structure. In a preferred embodiment, the panel may be extruded monolithically from aluminum. Also disclosed are systems for assembling structures from the panels utilizing a plurality of other components, which are also preferably extruded from aluminum.