Composite Building Panel with Embedded Steel Reinforcement
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Solution Overview
Problem
Current building panels with three layers of concrete and loose foam insulation lack tensile and shear strength, making them susceptible to delamination under high winds and prone to cracking or shattering from impact, while also having low insulation values leading to significant heating and cooling losses.
Innovation Solution
A composite panel structure featuring a concrete layer, a polyurethane insulation layer, and a corrugated steel layer with a reinforcing assembly that includes embedded vertical members and studs, which provide high compression, tensile, and shear strength, and are designed to withstand high winds and vertical loads, with the insulation layer formed in situ between the concrete and corrugated layers to maximize bonding and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If loose foam insulation is sandwiched between concrete layers, then insulation value is improved, but tensile and shear strength deteriorates
Solution Approach 1:
The patent employs a composite structure consisting of concrete layers bonded to corrugated steel layers with insulation material positioned between them. The concrete provides compression strength and fire resistance, the steel provides tensile and shear strength, and the insulation provides thermal resistance. This composite arrangement resolves the contradiction by combining materials with complementary properties to achieve high insulation value while maintaining structural strength.
Solution Approach 2:
The panel is segmented into distinct functional layers: concrete layers for structural compression strength, corrugated steel layers for tensile and shear strength, and insulation material for thermal resistance. This segmentation allows each layer to perform its specialized function, resolving the contradiction between insulation value and structural strength by distributing these requirements across separate material layers.
2Stress or pressure
If concrete layers are used for compression strength, then compression strength is improved, but resistance to delamination under shear forces deteriorates
Solution Approach 1:
The patent combines concrete layers with corrugated steel layers bonded together. The concrete provides compression strength while the steel provides resistance to shear forces and delamination. The adhesive bonding between layers creates a composite structure where the steel reinforcement prevents the concrete layers from delaminating under shear stress, resolving the contradiction between compression strength and delamination resistance.
Solution Approach 2:
The corrugated steel layers are strategically positioned at specific locations within the panel structure, particularly at interfaces between concrete layers, to provide localized reinforcement against shear forces and delamination. This local quality enhancement allows the concrete to maintain its compression strength while the steel provides targeted resistance to delamination where shear forces are most critical.
3Loss of energy
If high insulation value is achieved, then heating and cooling losses are reduced, but structural integrity under high winds and vertical loads deteriorates
Solution Approach 1:
The patent creates a multi-layer composite panel where concrete layers provide compression strength and fire resistance, corrugated steel layers provide tensile and shear strength for withstanding high winds and vertical loads, and insulation material provides high thermal resistance. This composite structure resolves the contradiction by allowing each material to contribute its superior properties, achieving high insulation value while maintaining structural integrity through the combined strength of concrete and steel.
Solution Approach 2:
The panel is divided into functionally segmented layers: structural concrete layers for compression and fire resistance, structural steel layers for wind and load resistance, and insulation layers for thermal performance. This segmentation enables the structure to achieve high insulation values without compromising structural integrity, as the structural and insulation functions are performed by separate, optimized material layers.
Data Source
AI summary
A building panel structure and a process for manufacturing the structure are disclosed. The structure comprises a concrete layer disposed on the outside of a building, an insulating material comprising polyurethane in the center of the structure and a corrugated steel layer on the inside of the building. A reinforcing assembly comprising an upper channel and a lower channel that are connected using a plurality of studs is embedded inside the building panel structure. The process of manufacturing the building structure comprises placing a wet concrete layer inside a container, positioning the reinforcing assembly in the container inside the wet concrete, setting the concrete layer and forming the polyurethane layer between the concrete and corrugated steel layers by an in-situ chemical reaction.