Layered Panels with Cement-Bonded Particle Board for Modular Building

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Solution Overview

Problem

Existing building construction methods require heavy materials, skilled labor, and complex processes, leading to high costs and inefficiencies, particularly in remote locations.

Innovation Solution

A layered panel comprising a prefabricated cement-bonded particle board (CBPB) with a supporting structure and metal grid, allowing for on-site assembly using fastening elements, reducing the need for heavy equipment and skilled labor, and enabling faster, cost-effective construction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional heavy materials (stone, bricks, cement, mortar) are used for building construction, then structural strength and stability are improved, but transport cost increases and waste generation increases

Engineering Contradiction:

Improvestructural strengthVSAvoidmaterial waste and transport cost

Core Design Contradiction:

StrengthVSLoss of substance

Solution Approach 1:

The patent uses composite materials consisting of a metal grid framework combined with cement-bonded particle board layers. This composite structure provides the necessary structural strength while using lighter materials compared to traditional heavy construction materials, thereby reducing transport costs and waste generation.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The building structure is divided into modular panels that can be manufactured separately and then assembled on-site. Each panel consists of segmented components (metal grid, particle board layers, fastening elements) that can be transported efficiently and assembled to create the overall structure, reducing the need for heavy materials during transport.

Inventive Principle:

Principle #1Segmentation

2Productivity

If prefabricated concrete walls are used, then construction speed is improved, but skilled labor and heavy equipment requirements increase

Engineering Contradiction:

Improveconstruction speedVSAvoidequipment and skilled labor requirements

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The panel design enables unskilled labor to assemble the structure using simple fastening elements that can be manually operated. The metal grid and particle board components are designed to be easily attached without requiring complex equipment or specialized skills, allowing the structure to be assembled by general laborers.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent employs simple, inexpensive fastening elements (such as screws, bolts, or clips) that can be easily installed and removed by manual labor. These simple fastening components replace the need for complex heavy equipment and skilled welding or concrete pouring operations, enabling faster assembly by unskilled workers.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Adaptability or versatility

If metal frame and multiple layers with specific functions are combined, then panel functionality is improved, but manufacturing complexity and equipment requirements increase

Engineering Contradiction:

Improvepanel functionalityVSAvoidmanufacturing equipment complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The panel is segmented into distinct functional components: a metal grid providing structural support, cement-bonded particle board layers providing insulation and finishing surfaces, and separate fastening elements for assembly. This segmentation allows each component to be manufactured independently using simple processes, avoiding the need for complex integrated manufacturing equipment.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The panel components (metal grid, particle board layers) are pre-manufactured separately and then assembled on-site using simple fastening elements. This preliminary preparation of individual components allows for simple manufacturing processes at the factory level, while the final assembly on-site requires only basic tools and unskilled labor, avoiding complex manufacturing equipment requirements.

Inventive Principle:

Principle #10Preliminary action

4Manufacturing precision

If mortar layer is projected evenly across the panel using machinery and vibrators, then manufacturing precision is improved, but time consumption and equipment requirements increase

Engineering Contradiction:

Improvemortar layer evennessVSAvoidmanufacturing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent replaces complex mortar projection machinery and vibrators with simple fastening elements that can be manually installed. The cement-bonded particle board layers are pre-manufactured with even surfaces using simple pressing or molding techniques, eliminating the need for time-consuming mortar projection and vibration processes while maintaining manufacturing precision.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Data Source

PatentUS20250290315A2Layered panel and method of construction thereof

Publication Date: 2025.09.18 ABB (SCHWEIZ) AG

AI summary

Described herein is a layered panel for on-site modular construction of buildings. The layered panel includes a layer formed by a prefabricated cement-bonded particle board, a supporting structure and fastening elements attaching the pre-fabricated cement-bonded particle board to the supporting structure. Also described herein is a method for manufacturing the layered panel, an installation for manufacturing the layered panel and a method for the construction of buildings with a plurality of the layered panels.