Composite Panel with Glass Through Elements and Sintered Plastic Structure
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Solution Overview
Problem
Current methods for manufacturing composite panels with glass through elements are inefficient, leading to high production costs, complex machinery requirements, and poor-quality panels due to misalignment and breakage of glass elements, as well as increased weight and difficulty in handling and transportation.
Innovation Solution
A composite panel design featuring glass through elements with a sintered heat-expanded plastic structure that anchors the glass elements, reducing the volume of cementitious mortar and distributing it in a way that the glass elements are securely embedded, allowing for easier handling and transportation, while maintaining mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional methods with two-dimensional supporting structures are used to cast cementitious mortar, then the panel can be manufactured, but the glass elements misalign and break due to multiple thrusts during casting
Solution Approach 1:
The glass elements are pre-assembled with the three-dimensional supporting structure before the cementitious mortar is cast. This preliminary assembly ensures proper positioning and alignment is established before the casting process begins, preventing misalignment and breakage during mortar insertion.
Solution Approach 2:
A three-dimensional supporting structure acts as an intermediary between the glass elements and the cementitious mortar. This structure provides a stable framework that holds the glass elements in their correct positions and distributes the thrust forces during casting, preventing direct impact on the glass elements.
2Illumination intensity
If glass sheets with peripheral frames are used as through elements, then light transmission is achieved, but the structure becomes complex and requires high number of operations for roughing and sectioning
Solution Approach 1:
The peripheral frames are removed from the glass sheets, extracting only the necessary light-transmissive function. The glass elements are used in their simplest form without additional framing structures, reducing overall panel complexity while maintaining light transmission capability.
Solution Approach 2:
Instead of using glass sheets that require roughing and sectioning operations, the invention inverts the approach by using individual glass elements that are directly positioned and embedded in the cementitious mortar, eliminating the need for post-casting mechanical operations.
3Strength
If cementitious mortar is used as the base material for composite panels, then mechanical strength is achieved, but the panel weight increases and handling becomes difficult
Solution Approach 1:
The cementitious mortar is used only in the necessary locations to provide structural support and embed the glass elements, rather than forming the entire panel. This localized use of heavy material reduces overall panel weight while maintaining mechanical strength where required.
Solution Approach 2:
The panel uses a composite structure combining cementitious mortar with three-dimensional supporting structures and glass elements. This composite approach allows the panel to achieve mechanical strength through the combination of materials rather than relying solely on heavy cementitious mortar, reducing overall weight.
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
The solution results in a lighter, easier-to-handle panel with improved mechanical properties and reduced production costs, achieved through the use of a sintered heat-expanded plastic structure that securely embeds glass elements, enhancing the manufacturing efficiency and quality of the panels.
Implementation Method 1
an inner structure made of sintered heat-expanded plastic material about the through elements
Implementation Method 2
sintered heat-expanded plastic material
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention relates to a composite panel (1) made of pourable and settable material, preferably cementitious mortar. The panel comprises through elements (10) made of glass for transmitting light between two base surfaces (1,1') of the panel (1). The panel comprises a structure (5) made by sintering heat- expanding plastic material about said through elements (10) so that a central part (12) of said through elements (10) is incorporated into said structure (5). The panel further comprising a first main portion (23) and a second main portion (24), each of which incorporates an end part (13,14) of the through elements (10). The two main portions (13, 14) are connected by a plurality of through portions (25) in said base material which extend through the inner structure (5). The present invention further relates to a semi-finished product (8) for making said panel (1) and to a method for making said panel base on the use of said semi-finished product (8).