Cellulose Composite Wall Panels with Wavy Profiles
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Solution Overview
Problem
Current methods for constructing buildings using corrugated cardboard face challenges such as reduced insulating effect, material weakening due to folding, transportation limitations, and complex corner connections, making it unsuitable for multi-story buildings and efficient installation.
Innovation Solution
A cellulose composite element system where panels with wavy or meandering profiles are connected using reinforced edge connectors made of compatible materials like wood, metal, or concrete, eliminating the need for folding and allowing for efficient assembly and installation, while maintaining high compressive and tensile strength and thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If corrugated cardboard is folded multiple times to create wall panels, then the material can be assembled into building structures, but the insulating effect is reduced and the material strength is weakened
Solution Approach 1:
The wall panel is divided into multiple separate corrugated cardboard layers that are stacked and connected at edges rather than folded into each other. Each layer remains intact with its full insulating and strength properties, while the segmentation allows for modular assembly into wall structures.
Solution Approach 2:
Multiple corrugated cardboard layers are nested stacked on top of each other, with each layer maintaining its complete corrugated structure. The layers are positioned one above another like nested dolls, preserving the insulating air pockets within each layer while achieving the desired wall panel configuration through vertical stacking.
2Ease of manufacture
If corrugated cardboard is folded to create wall panels, then assembly is possible, but the insulating effect is reduced
Solution Approach 1:
The wall panel is divided into multiple separate corrugated cardboard layers that are stacked and connected at edges rather than folded into each other. Each layer remains intact with its full insulating and strength properties, while the segmentation allows for modular assembly into wall structures.
Solution Approach 2:
Multiple corrugated cardboard layers are nested stacked on top of each other, with each layer maintaining its complete corrugated structure. The layers are positioned one above another like nested dolls, preserving the insulating air pockets within each layer while achieving the desired wall panel configuration through vertical stacking.
3Length of stationary object
If large hollow bodies are created for multi-story buildings, then building height increases, but transportation becomes prohibitively difficult
Solution Approach 1:
The wall panels are segmented into standardized modular units of manageable dimensions that can be easily transported using conventional means. These modular panels are then assembled on-site to create walls of any required height for multi-story buildings, eliminating the need to transport entire large hollow building structures.
Solution Approach 2:
The corrugated cardboard layers and connecting elements are prepared and pre-assembled into complete wall panels at the manufacturing location. This preliminary assembly into transportable modules allows for efficient production and distribution, with final building construction occurring through straightforward on-site installation of these pre-prepared panels.
4Stability of the object's composition
If corner connections are created for corrugated board walls, then structural continuity is achieved, but the connection complexity increases
Solution Approach 1:
The connecting elements are designed with universal functionality to handle all corner and joint connections between wall panels. A single standardized connector design can be used at any corner or T-junction, providing structural continuity while eliminating the need for specialized corner connection components or complex assembly procedures.
Solution Approach 2:
Instead of creating complex corner connections by folding or specially shaping the corrugated cardboard at corners, the invention inverts the approach by using simple flat panels connected through standardized external connecting elements. The corner strength is achieved not by complex corner geometry but by the robust standardized connectors that join panels at standardized connection points.
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
Enables cost-effective, energy-efficient, and recyclable building construction suitable for multi-story buildings, with improved load-bearing capacity, thermal insulation, and ease of transportation and installation, using cellulose composite elements with integrated panel connectors that enhance structural stability and insulation.
Implementation Method 1
adhesive which bonds the cellulose fibers to one another and/or the sheets or thin plates to one another
Implementation Method 2
a sheet of paper or piece of paperboard can withstand significantly greater compressive forces if it is curved in a columnar or tube-like manner because this partially relieves the compressive forces in the now curved surface of the paper be derived to tensile forces
Implementation Method 3
the cavities of which are filled with polyurethane foam
Data Source
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AI summary
Disclosed is a composite cellulose element for drywalling walls, ceilings, and floors of buildings. Said composite cellulose element is composed of cellulose-containing material with hollow spaces that are enclosed therein. Each board comprises several layers of sheets or thin boards, said layers being glued together. Several of the layers of sheets or thin boards have the profile of a wave or a meander. Numerous hollow spaces are formed within said profile. Several boards can be connected to one other.