Concrete Wall Panels With Flexible Polymer Insulation

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Solution Overview

Problem

Current building materials, such as structural lightweight concrete and autoclave aerated concrete, face challenges with brittleness, high energy consumption, and difficulty in installation, particularly in curved or irregular geometries, and lack effective thermal insulation and structural support.

Innovation Solution

Cement panels with a flexible polymer layer, such as polyolefin foam, sandwiched between cement layers, allowing for orthogonal rebar placement and enabling the panels to be set in planar, curved, or polyhedral cross-sectional shapes, providing enhanced thermal insulation and structural support.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If XPS board is used as insulation material in concrete wall panels, then thermal insulation performance is improved, but brittleness increases and installation complexity increases

Engineering Contradiction:

Improvethermal insulation performanceVSAvoidinstallation ease

Core Design Contradiction:

Loss of energyVSEase of operation

Solution Approach 1:

The patent changes the physical state and mechanical properties of the insulation material from rigid (XPS) to flexible (polymer foam), maintaining thermal insulation performance while dramatically improving ease of installation and eliminating brittleness issues

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite wall panel system combining concrete layers with flexible polymer foam insulation, where the concrete provides structural strength and the polymer foam provides thermal insulation with flexibility

Inventive Principle:

Principle #40Composite materials

2Weight of moving object

If lightweight concrete is used to reduce building weight, then weight is reduced, but strength decreases and durability concerns arise

Engineering Contradiction:

Improvebuilding weightVSAvoidconcrete strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent uses a composite construction with dense concrete outer layers providing strength and durability, while the flexible polymer foam core provides lightweight insulation, achieving both weight reduction and strength maintenance

Inventive Principle:

Principle #40Composite materials

3Loss of energy

If conventional rigid insulation materials are used, then thermal insulation is provided, but adaptability to curved or irregular geometries is reduced

Engineering Contradiction:

Improvethermal insulationVSAvoidgeometric adaptability

Core Design Contradiction:

Loss of energyVSAdaptability or versatility

Solution Approach 1:

The patent changes the flexibility parameter of the insulation material from rigid to highly flexible, enabling the material to conform to curved, angled, and irregular geometries while maintaining continuous thermal insulation coverage

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The flexible polymer foam insulation can be dynamically shaped and formed into various geometries during installation, allowing adaptation to different architectural designs including curved walls and irregular surfaces

Inventive Principle:

Principle #15Dynamics

4Strength

If reinforcing steel is added to concrete walls for structural support, then strength is improved, but installation difficulty increases due to utilities

Engineering Contradiction:

Improvestructural supportVSAvoidinstallation difficulty

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The flexible polymer foam insulation layer can be easily cut and shaped to accommodate plumbing and electrical utilities without requiring complex reinforcing steel arrangements, simplifying installation around building services

Inventive Principle:

Principle #30Flexible shells and thin films

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 offers improved thermal resistance, reduced thermal conductivity, and ease of installation in complex geometries, while maintaining structural integrity and cost-effectiveness, making it suitable for energy-efficient building construction.

Implementation Method 1

an insulation layer comprising flexible polymer... providing enhanced thermal insulation and structural support

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS11572683B2Concrete wall panels with flexible insulation material

Publication Date: 2023.02.07 KING FAHD UNIVERSITY OF PETROLEUM AND MINERALS

AI summary

A structural, load-bearing panel useful in constructing multistory buildings may have a panel height, panel width, and panel thickness, and may include a first layer comprising at least 75 wt. % of concrete, relative to a total weight of the first layer; an insulation layer comprising flexible polymer, the insulation layer having a thickness of at least 5 cm; and a second layer comprising at least 75 wt. % concrete, wherein the insulation layer is sandwiched between the first and second layers, and wherein the panel is suitable to be set in any of a planar, curved, and polyhedral cross-sectional shape. Set panels are not flexible, though the flexibility of the insulation layer, particularly of a polyethylene foam, may allow the panel to have a curved, or polyhedral cross-section while still serving as a structural support.