Composite Wall Element With Pressure Relief for Thermal Stress

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Solution Overview

Problem

Existing prefab concrete walls have limited reusability, high energy consumption in production, and are not environmentally sustainable.

Innovation Solution

A wall element composed of a plane-like layer with embedded profiles and a pressure reducing element, using casting mortar with profiles to create a lightweight, recyclable structure that absorbs pressure differences due to thermal expansion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional concrete wall elements are used, then structural strength is ensured, but weight and environmental impact of transportation increase

Engineering Contradiction:

Improvestructural strengthVSAvoidweight of wall element

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The wall element uses a composite structure combining casting mortar (providing rigidity and low expansion coefficient) with metal profiles (providing structural strength and connectivity). This composite approach allows the wall element to achieve required strength while reducing overall weight compared to traditional concrete walls, thereby reducing transportation environmental impact

Inventive Principle:

Principle #40Composite materials

2Stability of the object's composition

If traditional concrete wall elements are used, then structural stability is ensured, but reusability and sustainability are limited

Engineering Contradiction:

Improvestructural stabilityVSAvoidreusability

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The wall element is segmented into distinct components: a casting mortar layer and separate profiles that can be embedded or connected. This segmentation allows the profiles to be reused in subsequent constructions while the mortar layer can be recycled, significantly improving reusability and sustainability compared to monolithic concrete walls

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The design enables easy separation and recovery of the profiles from the casting mortar layer. The profiles can be extracted and reused in new wall elements, while the casting mortar can be processed and recycled, thereby enhancing the overall reusability and sustainability of the construction system

Inventive Principle:

Principle #34Discarding and recovering

3Strength

If profiles are extensively used in the wall element, then structural strength is improved, but material consumption and complexity increase

Engineering Contradiction:

Improveload-bearing capacityVSAvoidmaterial consumption

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

Profiles are strategically positioned only where structurally necessary - embedded in the casting mortar at critical locations for load-bearing and connectivity. This localized placement ensures adequate strength while minimizing the total quantity of profile material required, avoiding unnecessary material consumption

Inventive Principle:

Principle #3Local quality

4Adaptability or versatility

If profiles with different expansion coefficients are connected, then design flexibility is improved, but thermal stress and damage risk increase

Engineering Contradiction:

Improvedesign flexibilityVSAvoidthermal stress

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

A pressure reducing element is introduced as an intermediary component between profiles with different expansion coefficients. This intermediary absorbs and compensates for differential thermal expansion, preventing stress concentration and potential damage at connection points while allowing the use of diverse profile materials for design flexibility

Inventive Principle:

Principle #24Intermediary (Mediator)

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 lightweight, low-carbon footprint wall element with high recyclability, reduced material use, and enhanced durability by absorbing thermal stress, allowing for efficient construction and sustainable building practices.

Implementation Method 1

pressure differences caused by differences in the expansion coefficients between the casting mortar of the layer and the profiles

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

the pressure reducing element being deformable (and usually compressible), thus allowing it to be compressed under said pressure differences in order to reduce the pressure

Methodology Applied

Scientific EffectDeformation: Deformation

Data Source

PatentUS12584312B2Wall element, wall and building as well as method for construction

Publication Date: 2026.03.24 ECOWAND IP BV

AI summary

Wall element for manufacturing a wall of a building, comprising: a substantially planar shell (4) having a peripheral edge, the shell comprising casting mortar (G); one or more profiles (14, 16) at least partially embedded in the shell (4) and provided with at least one joining surface positioned outside the shell when viewed from a shell surface, each of the profiles (14, 16) being provided with a respective connection surface (24, 26); and at least one pressure-reducing element (30, 32) operatively connected to at least a part of the one or more profiles. The invention relates also to a wall and/or a building built up of such wall plates and a method for manufacturing a wall element.