Building Panels with Filamentous Scrim for Hail and Wind Resistance

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Solution Overview

Problem

Existing building construction panels, particularly roofing panels, face challenges with hail resistance, wind uplift, and installation efficiency due to exposure to extreme environmental conditions and labor-intensive installation processes, leading to potential damage and increased costs.

Innovation Solution

The development of building panels incorporating a structural core with a filamentous scrim and a nonwoven mat facer, which enhances hail resistance and wind uplift performance while allowing for simpler and faster installation using fewer fasteners.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional building panels are used, then installation is simpler, but hail resistance and wind uplift performance are insufficient

Engineering Contradiction:

Improvehail resistanceVSAvoidpanel structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies composite materials by combining a structural core with a filamentous scrim layer to create a panel that achieves Very Severe Hail resistance. The scrim-reinforced composite structure provides the necessary strength and durability against hail and wind uplift while maintaining installation feasibility through integrated design

Inventive Principle:

Principle #40Composite materials

2Productivity

If traditional building panels are used, then material costs are lower, but installation time and labor costs increase

Engineering Contradiction:

Improveinstallation speedVSAvoidmanufacturing complexity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent applies segmentation by dividing the panel into distinct functional layers: a structural core and a filamentous scrim layer. This segmentation allows each component to be optimized independently for its specific function while being manufactured as an integrated unit, reducing overall manufacturing complexity and enabling faster installation

Inventive Principle:

Principle #1Segmentation

3Strength

If more fasteners are used, then wind uplift resistance improves, but installation time and costs increase

Engineering Contradiction:

Improvewind uplift resistanceVSAvoidinstallation time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The patent applies the principle of shape optimization by using a filamentous scrim with specific geometric configuration that distributes wind uplift forces across the panel surface. This curvature-based reinforcement structure achieves high wind uplift resistance (exceeding 240 lb/ft²) while requiring fewer fasteners, reducing installation time and labor costs

Inventive Principle:

Principle #14Spheroidality (Curvature)

Data Source

PatentUS20230265653A1Building panels, assemblies, and associated methods

Publication Date: 2023.08.24 GEORGIA PACIFIC GYPSUM LLC

AI summary

Building panels, assemblies of building panels, and associated methods are provided. A building panel includes a structural core, such as a set gypsum core, at least one filamentous scrim associated with the core, and a nonwoven mat facer.