Custom Building Panel Fabrication via Sacrificial Relief and Foam
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Solution Overview
Problem
Constructing building structures with complex shapes and multiple materials is challenging due to the need for mechanical fasteners, which can compromise thermal and moisture integrity, and existing 3D printing methods do not efficiently fabricate customized building panels on-site.
Innovation Solution
The method involves building a sacrificial relief using multilayer deposition of a sacrificial material to create a contour for the façade layer, which is then covered with a foamable composition that expands into polymeric foam, allowing components to be adhered without penetrating fasteners, enabling on-site fabrication of complex-shaped panels with integrated thermal, acoustical, and structural properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical fasteners are used to attach building components, then structural strength is improved, but thermal integrity and moisture barrier properties deteriorate
Solution Approach 1:
The patent introduces an adhesive layer as an intermediary substance between building components. This adhesive serves as a mediator that bonds components together without requiring mechanical fasteners to penetrate through the components, thereby maintaining thermal integrity and moisture barrier properties while achieving structural strength through chemical bonding rather than mechanical penetration.
2Productivity
If prefabricated panels are manufactured and shipped to construction sites, then construction speed is improved, but fabrication flexibility and customization capability deteriorate
Solution Approach 1:
The patent applies preliminary action by preparing all necessary components, materials, and adhesive systems before the actual panel fabrication at the construction site. This includes pre-mixing adhesives, pre-preparing substrate panels, and having all required materials on-site, which enables rapid assembly while maintaining the ability to customize the panel design right at the construction location without requiring remote prefabrication.
3Shape
If complex shapes are fabricated through extensive bending and molding, then shape complexity is improved, but fabrication difficulty and time consumption increase
Solution Approach 1:
The patent utilizes parameter changes by employing adhesive formulations with specific rheological properties and curing characteristics that enable the bonding of complex-shaped components. The adhesive parameters (viscosity, curing time, temperature range) are optimized to allow fabrication of complex shapes through controlled application and curing processes, reducing the need for extensive bending and molding operations while maintaining shape complexity.
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 approach allows for defect-free façade layers and the creation of customized building panels with integrated thermal insulation, moisture, and air barrier properties, avoiding thermal shorts and moisture breaches, while enabling last-minute design changes and reducing fabrication and shipping costs.
Implementation Method 1
depositing a foamable composition over the façade layer; wherein the foamable composition expands into polymeric foam that is adhered to the façade layer
Data Source
Figure 1
AI summary
Fabricate a panel (5) by building a sacrificial relief (10) by an additive process of multilayer deposition, applying a facade layer (20,30) over the sacrificial relief so as to conform to the contour of the sacrificial relief, depositing a foamable composition (40, 50, 60) over the facade layer.