Fiber-Stabilized Stone Sandwich Wall Panels
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Solution Overview
Problem
Existing wall constructions using concrete or brick are heavy and inefficient in distributing compressive forces, while materials like natural stone and ceramics are brittle and prone to fracture under tensile and bending loads, making them unsuitable for load-bearing purposes without additional stabilization.
Innovation Solution
A symmetrical sandwich construction using pressure-resistant earthenware or ceramic slabs stabilized with fibrous carrier materials and a shear-resistant insulating foam core, where the coefficient of expansion is minimized to maintain dimensional stability across temperature and pressure ranges, allowing the slabs to absorb compressive forces and resist mechanical and thermal loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If thin earthenware slabs are used to reduce weight and material consumption, then the wall construction becomes lighter and more material-efficient, but the slabs become unstable under tensile and bending loads and are prone to fracture
Solution Approach 1:
The patent combines thin earthenware slabs with a fibrous stabilizer material and insulating foam core to create a composite sandwich structure. The earthenware provides compressive strength and aesthetic surface, while the fibrous stabilizer prevents thermal expansion-induced bending and the foam core provides shear resistance and structural rigidity, together enabling the thin slabs to bear loads safely
Solution Approach 2:
The stabilizer material is applied selectively on the back side of the earthenware slabs where tensile and bending stresses occur, providing localized reinforcement exactly where needed. This allows the slabs to maintain their thin, lightweight design while gaining stability in the critical stress zones
2Strength
If the wall construction uses conventional concrete or brick to provide structural support, then the load-bearing capacity is sufficient, but the construction becomes heavy and material consumption increases
Solution Approach 1:
The patent replaces heavy concrete or brick with a composite sandwich structure combining earthenware slabs, fibrous stabilizer, and foam core. This composite achieves comparable or superior load-bearing capacity through the synergistic combination of materials: earthenware for compression, fibrous stabilizer for tensile resistance, and foam core for shear resistance, while dramatically reducing weight
Solution Approach 2:
The wall construction is segmented into distinct functional layers: outer earthenware slabs for compression and aesthetics, fibrous stabilizer layer for tensile reinforcement, and foam core for shear resistance and insulation. This segmentation allows each material to be optimized for its specific function, achieving high strength-to-weight ratio
3Productivity
If earthenware slabs are stabilized with fibrous carrier material and foam core to reduce weight, then the load-bearing efficiency increases, but the construction complexity increases
Solution Approach 1:
The patent merges multiple functions into a single integrated sandwich panel: the foam core serves as both the structural shear-resistant element and the thermal insulator, while the fibrous stabilizer simultaneously prevents thermal expansion effects and provides tensile reinforcement. This merging reduces the number of separate components and simplifies construction despite the advanced material composition
4Use of energy by stationary object
If the wall construction uses asymmetrical design with insulating material on one side, then the thermal insulation is provided, but the structural efficiency and material distribution are suboptimal
Solution Approach 1:
The patent employs asymmetrical placement of the foam core within the sandwich structure, positioning it to optimize both thermal insulation performance and structural load distribution. The asymmetrical design allows the insulating material to be strategically located where it provides maximum thermal benefit while maintaining structural integrity, rather than symmetric distribution
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, self-supporting wall construction that is twice as efficient in load-bearing capacity as conventional concrete or steel, while maintaining a straight and flat surface, reducing material and space requirements by 15-50% and achieving thermal insulation standards like Minergie.
Implementation Method 1
the core of the invention relates to a new type of technology for creating a house wall as a building element... it is not only necessary to stabilize the earthenware or ceramic tiles against tension and the associated breakage, but also to set a pressure gradient on the stone side to be stabilized at the interface between the stone to be stabilized and the stabilizer that practically approaches zero
Implementation Method 2
Between the plates is the insulating layer, which stiffens the construction across the cross section
Implementation Method 3
The two plates absorb the compressive forces and consist of particularly pressure-resistant material such as natural stone, artificial stone of all types, concrete and other earthenware
Data Source
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AI summary
The invention describes the construction of more or less thin house walls, with supporting plates thereof being stabilized such that said plates utilize an insulating middle layer for stiffening across the cross section. In particular, natural stone plates are used, which become self-supporting wall and facade elements with the aid of fiber reinforcement. Fiber-stabilized stone panels comprising an insulating layer made of foam material in the middle layer are configured symmetrically and are thus dimensioned in such a way that they can absorb support loads and buckling loads while maintaining a comparatively very low weight.