Frameless Structural Insulated Panel with Stone Finish
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Solution Overview
Problem
Existing building panel technologies face challenges such as energy inefficiency, moisture control issues, and high construction waste due to poorly designed material dimensions, and they often rely on frames that can fail over time or in extreme weather conditions.
Innovation Solution
The development of pre-assembled, multi-layered structural insulated panels (SIPs) composed of cement-particle panels, polystyrene foam thermal insulation, and a natural stone finish, which are manufactured in a factory using a controlled process to ensure airtight and hermetic construction elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional frame construction with screws, nails and glue is used, then panels can be assembled on-site, but the frame can fail over time or in extreme weather conditions
Solution Approach 1:
The patent removes the traditional wooden or metal frame from the panel construction, extracting the problematic element that causes failure over time. The frameless design eliminates screws, nails, and glue joints that are prone to failure, while the panel edges are directly connected through interlocking mechanisms or adhesive bonding of the panel surfaces themselves.
Solution Approach 2:
The structural frame function is merged into the panel edges themselves. The cement-particle panels are designed with reinforced edges that directly bear structural loads, eliminating the need for separate framing elements. This integration of structural support into the panel material itself resolves the contradiction between reliability and complexity.
2Reliability
If membranes and sealants are used for moisture control and sealing, then air tightness is achieved, but these materials can fail over time and be poorly installed
Solution Approach 1:
The sealing and moisture control functions are built into the panel manufacturing process itself. Adhesive layers are applied to the panel edges during factory production, creating permanent seals before the panels are installed on-site. This preliminary action eliminates the need for complex field installation of membranes and sealants, ensuring consistent quality and long-term reliability.
Solution Approach 2:
The sealing function is merged with the structural panel assembly. The adhesive layers serve dual purposes: bonding the cement-particle panels to the insulation core and simultaneously providing airtight sealing and moisture control. This consolidation eliminates separate sealing materials and installation steps.
3Ease of manufacture
If standard panel dimensions are used, then manufacturing is simplified, but construction waste increases due to poor dimension matching
Solution Approach 1:
The patent employs customizable panel dimensions that can be precisely adjusted to match specific building design requirements. The manufacturing process is flexible enough to produce panels in various sizes and configurations, allowing for optimal material utilization and minimizing cuts and waste during construction, while maintaining standardized production methods.
4Reliability
If cement-particle panels with adhesive layers are used, then airtight hermetic construction is achieved, but manufacturing precision requirements increase
Solution Approach 1:
The adhesive layers are applied to the panel edges during factory manufacturing under controlled conditions, ensuring precise and uniform coverage before the panels are shipped and installed. This preliminary application of adhesives in the manufacturing process eliminates the need for precision field work and ensures consistent airtight sealing.
Solution Approach 2:
The adhesive layers are strategically applied to specific zones on the panel edges where sealing is most critical, rather than requiring uniform precision across entire panel surfaces. This localized approach to adhesive application maintains airtightness while reducing overall manufacturing precision requirements.
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 enhances energy efficiency, reduces construction waste, and provides a durable, airtight building envelope that minimizes thermal bridging and environmental exposure, while allowing for quick and efficient on-site assembly.
Implementation Method 1
Adhesive layers are placed between the first panel and the layer of heat-insulating material and between the second panel and the thermal-insulating material
Implementation Method 2
a layer of polystyrene foam thermal insulation material placed between the two panels
Implementation Method 3
a natural stone finish panel that additionally provides a more suitable surface for attaching vacuum suction devices for lifting the panels
Data Source
Figure 1a~1b
Figure 2a~3
Figure 4~5
AI summary
A sealed and hermetic structural insulated panel comprising a first cement-particle panel (1.1), a second cement-particle panel (1.2) and a layer of polystyrene foam thermal insulation material (3) interposed therebetween, a natural stone finish panel (4) on the second cement-particle panel (1.2) is disclosed. The natural stone finish panel (4) includes a surface for attaching vacuum suction holders of the lifting equipment. Also disclosed is a method of manufacturing a structural insulated panel comprising forming a frameless structure from a first cement-particle panels (1.1), polystyrene foam layer (3), second cement-particles panels (1.2), polyurethane adhesive layers (2.1, 2.2, 2.3) and stone finishing panels (4). The use of structural insulated panels for building construction is also disclosed. Application involves mounting the panels to a wooden frame with glue, mechanically pressing them into place and mechanically tightening them using vacuum suction mounts.