Composite Wall Panel with Integrated Formwork and Utility Channels
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Solution Overview
Problem
Existing wall construction methods are labor-intensive, costly, and lack efficient integration of insulation, utilities, and structural flexibility, particularly for industrial and commercial buildings, with concrete tilt-up systems posing challenges in handling, thermal insulation, and accommodating varying structural requirements.
Innovation Solution
A composite wall system comprising a laminated panel with an insulation layer and a lining layer, incorporating formwork members that allow for variable column sizes and integrated utility channels, eliminating the need for additional linings and mesh coverings, and enabling lightweight, easily assembled panels coated with concrete to form a structurally sound wall.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If precast concrete sections are transported to site for erection, then wall construction speed is improved, but transportation costs and handling difficulty increase
Solution Approach 1:
The wall panel is divided into a lightweight core section and a separate concrete coating layer. The core section can be transported and erected easily, then the concrete coating is applied on-site to provide structural strength and insulation, resolving the contradiction between construction speed and handling complexity.
Solution Approach 2:
The structural function and insulation function are separated into different layers (core section vs. concrete coating). This dimensional separation allows the lightweight core to be handled easily while the concrete coating provides the required structural properties after application.
2Strength
If solid concrete sections are used, then structural strength is improved, but thermal insulation performance deteriorates
Solution Approach 1:
The wall panel uses a composite structure combining a lightweight insulating core with a concrete coating layer. This composite design provides both structural strength from the concrete and thermal insulation from the core, resolving the contradiction between strength and insulation performance.
3Strength
If conventional wall construction methods are used, then structural integrity is improved, but labor intensity and construction time increase
Solution Approach 1:
The core section and insulation layers are pre-assembled into a complete panel structure before site erection. This preliminary assembly reduces on-site construction time and labor intensity while maintaining structural integrity through the integrated design.
Solution Approach 2:
Multiple functions (structural support, insulation, lining) are merged into a single integrated panel system. This consolidation eliminates the need for separate construction steps for each function, improving construction efficiency without compromising structural integrity.
4Adaptability or versatility
If variable column sizes are required for different engineering requirements, then adaptability is improved, but manufacturing complexity increases
Solution Approach 1:
The formwork members are designed to be adjustable in position and configuration, allowing the panel to accommodate variable column sizes and different engineering requirements. This dynamic adjustability provides structural adaptability without requiring complex custom manufacturing for each variation.
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
This solution simplifies construction by reducing labor requirements, integrating thermal insulation and utilities, and allowing for site-specific structural adaptations, resulting in faster and more uniform wall construction with reduced material needs and improved thermal performance.
Implementation Method 1
an insulation layer (14) providing a first face (18)
Data Source
Figure 1~2
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Figure 4
AI summary
A composite wall, ceiling or floor panel (10), system and method, including a sheet (14) having a first face (18) including at least one first mounting portion (16), and at least one formwork member (20) with at least one second mounting portion (30) arranged to engage with the first mounting portion of the sheet to retain the sheet and said at least one formwork member together. Structural support comes from piers (for a wall) or beams (ceiling or floor) formed in the spacing between adjacent formwork members. The formwork members act as the core of a wall, ceiling or floor panel. An external coating (123) is applied to the formwork members, such as spray shotcrete or render. Channels (28) formed by the formwork members defines integrated ducting for services to be run.