Composite Stud Wall Panel Ballistic Protection

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Solution Overview

Problem

Existing prefabricated blast or building panels made of reinforced concrete are heavy and prone to fragmentation under extreme loads, lacking effective lightweight solutions for ballistic protection.

Innovation Solution

A composite stud wall assembly comprising spaced metal studs with metal crossbars and a cementitious aggregate panel, where one side of the studs is embedded in the panel, and reinforced with a 0/90° metal or fiber polymer composite mesh, providing enhanced ballistic protection with reduced weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If reinforced concrete panels are used for blast protection, then ballistic protection is provided, but weight increases significantly

Engineering Contradiction:

Improveballistic protectionVSAvoidpanel weight

Core Design Contradiction:

StrengthVSWeight of stationary object

Solution Approach 1:

The patent applies composite materials by combining metal studs with cementitious aggregate panels to create a hybrid structure that achieves ballistic protection with reduced weight compared to solid reinforced concrete. The composite construction allows optimized weight-strength ratio.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The panel is segmented into discrete metal studs embedded in cementitious aggregate, rather than using monolithic reinforced concrete. This segmentation allows for reduced material usage while maintaining protective capabilities through the distributed stud structure.

Inventive Principle:

Principle #1Segmentation

2Strength

If reinforced concrete panels are used for blast protection, then structural strength is provided, but fragmentation occurs under extreme loads

Engineering Contradiction:

Improvestructural strengthVSAvoidfragmentation

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The composite structure of metal studs in cementitious aggregate provides ductile behavior and structural integrity under extreme loads, preventing the catastrophic fragmentation that occurs in monolithic reinforced concrete. The metal studs maintain structural coherence.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the material parameters from homogeneous reinforced concrete to a composite system with different mechanical properties, where the metal studs provide ductility and prevent brittle fragmentation under extreme loading conditions.

Inventive Principle:

Principle #35Parameter changes

3Strength

If metal studs are embedded in cementitious aggregate panel, then ballistic protection is enhanced, but manufacturing complexity increases

Engineering Contradiction:

Improveballistic protectionVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The metal studs are embedded in the cementitious aggregate panel during the panel manufacturing process itself, rather than as a separate post-installation step. This preliminary integration simplifies the overall construction process despite the complex composite structure.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11299886B2Composite stud wall panel assembly

Publication Date: 2022.04.12 PROTECTIFLEX LLC

AI summary

A composite stud wall panel assembly, which can be used alone as a blast panel or as a module for wall or roof structures, comprises a frame including a plurality of spaced apart metal studs and metal crossbars interconnecting the studs; and a cementitious aggregate panel, one side of the metal studs being embedded in and permanently connected to the panel along the length of the studs.