Blast Resistant Prefabricated Wall Units with Fiber-Reinforced Composite Panels
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Solution Overview
Problem
Existing prefabricated wall units are prone to fragmentation during explosive blasts, generating secondary projectiles that can cause additional damage, and lack the ability to absorb significant blast energy.
Innovation Solution
The use of a two-layer construction for prefabricated wall units, with a thermoset matrix resin-impregnated fiber-reinforcing layer bonded between exterior and interior walls, extending around top and sole plates, to prevent fragmentation and enhance blast resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional prefabricated wall units with sheetrock and masonry board layers are used, then ease of manufacture and standard construction practices are maintained, but the walls fragment into secondary projectiles during explosive blasts
Solution Approach 1:
The patent applies composite materials by bonding a fiber-reinforcing layer (such as glass fiber, aramid fiber, or steel reinforcement) to the sheetrock or masonry board layers. This creates a composite structure where the fiber-reinforcing layer prevents fragmentation while the outer layers maintain the conventional wall construction appearance and ease of manufacture. The composite material resolves the contradiction by providing blast resistance without sacrificing manufacturability.
Solution Approach 2:
The patent implements preliminary anti-action by pre-installing the fiber-reinforcing layer within the wall construction before blast events occur. This preliminary reinforcement counteracts the harmful fragmentation effect before it can manifest, preventing secondary projectiles from forming during explosive blasts while maintaining the wall's conventional structure and ease of manufacture.
2Ease of manufacture
If conventional prefabricated wall units are used, then standard construction methods are maintained, but the walls lack ability to absorb significant blast energy
Solution Approach 1:
The composite structure formed by bonding fiber-reinforcing layers to conventional wall materials creates an energy-absorbing system. The fiber-reinforcing layer deforms and absorbs blast energy through controlled deformation, while the conventional sheetrock and masonry board layers provide structural framework. This composite approach enables significant blast energy absorption while maintaining standard construction methods and ease of manufacture.
Solution Approach 2:
The fiber-reinforcing layer serves as a beforehand cushioning element within the wall construction. This preliminary reinforcement absorbs and cushions blast energy through deformation, protecting the conventional wall materials from direct blast forces while maintaining standard construction methods. The cushioning layer prevents energy transmission to the outer layers, reducing fragmentation and maintaining structural integrity.
3Strength
If adhesive-bonded web mesh panels are used to withstand high winds, then wind resistance is improved, but the panels cannot survive impacts from primary projects or shock waves
Solution Approach 1:
The patent creates a composite structure where fiber-reinforcing layers (such as glass fiber, aramid fiber, or steel reinforcement) are bonded to sheetrock or masonry board layers. This composite material provides both wind resistance through the structural framework and blast impact survival through the energy-absorbing fiber-reinforcing layers, overcoming the limitations of adhesive-bonded web mesh panels.
Solution Approach 2:
The patent changes the material parameters by introducing fiber-reinforcing layers with high strength-to-weight ratios and energy-absorption capabilities. These parameter changes enable the wall panels to survive blast impacts while maintaining wind resistance, transforming the panels from vulnerable adhesive-bonded structures to resilient composite structures capable of withstanding both wind and explosive loads.
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 effectively prevents the formation of secondary projectiles and allows the wall units to absorb considerable blast energy, maintaining structural integrity during explosive events.
Implementation Method 1
the reinforcement continuing around top and sole plates
Implementation Method 2
a matrix resin-impregnated fiber-reinforcing layer bonded between the layers
Data Source
AI summary
Blast resistant prefabricated wall panels contain at least one panel consisting of two structural boards having a thermoset resin-impregnated fiber reinforcing layer therebetween and extending from sides of the panel, the extension wrapped at least partially around metal sole and top plates of a metal sole plate, top plate, and stud construction. The panels are capable of resisting explosive blasts without forming secondary projectiles, and are preferably attached to a building structure by energy absorbing deformable brackets.