Fiber-Reinforced Polymeric Building Panels with Foam Insulation
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Solution Overview
Problem
There is a need for lighter weight structural building panels and improved methods for manufacturing them, particularly for applications where concrete is conventionally used in residential, commercial, and light industrial construction. Additionally, there is a need for building systems that are impermeable to water, including at joints in the wall.
Innovation Solution
The development of fiber-reinforced polymeric structural building panels, which consist of a main body fabricated with outer and inner fiber-reinforced polymeric layers, and load-bearing studs. The panels include foam blocks disposed between the inner and outer layers, which can be assembled into panel precursors using hand lay-up or pultrusion processes. The studs are typically pultruded and adhesively or mechanically fastened to the main body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional concrete structures are used for building walls and foundations, then strength and load-bearing capacity are achieved, but weight is excessive
Solution Approach 1:
The patent employs fiber-reinforced polymer (FRP) composite materials consisting of a polymer matrix reinforced with continuous fibers oriented in the direction of primary stresses. This composite structure provides high strength-to-weight ratio, enabling the panels to bear compressive and lateral loads while maintaining lightweight characteristics. The composite material replaces traditional concrete, achieving both strength requirements and weight reduction goals.
Solution Approach 2:
The building panels are divided into modular sections with standardized dimensions and configurations. Each panel is a self-contained unit with integrated features such as embedded anchors, insulation layers, and waterproofing membranes. This segmentation allows for efficient manufacturing, transportation, and assembly while maintaining structural integrity through standardized connection details.
2Weight of moving object
If fiber-reinforced polymeric materials are used to reduce weight, then weight is reduced, but manufacturing complexity increases
Solution Approach 1:
Reinforcing fibers are pre-aligned and pre-positioned in the desired orientation within the panel structure before polymer infiltration. This preliminary arrangement ensures optimal fiber orientation for load-bearing without requiring complex post-manufacturing adjustments. The fibers are arranged in patterns that match the expected stress distributions, simplifying the manufacturing process while maximizing structural efficiency.
Solution Approach 2:
Multiple manufacturing steps are combined into an integrated process where fiber reinforcement, polymer infiltration, curing, and waterproofing membrane application occur in a unified manufacturing sequence. This merging of operations reduces the number of separate manufacturing stages, minimizes handling steps, and simplifies the overall production process while maintaining product quality.
3Reliability
If building panels are designed to be impermeable to water, then waterproofing is achieved, but joint complexity increases
Solution Approach 1:
A waterproofing membrane is integrated as a continuous thin film layer within the panel structure, extending through the panel thickness and forming a seamless barrier. This membrane follows the contours of the panel geometry and maintains waterproofing integrity without requiring complex mechanical joint components. The flexible nature of the membrane allows it to accommodate thermal expansion and contraction while maintaining the waterproof seal.
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 resulting building panels are strong enough to bear compressive and lateral loads, providing a lightweight alternative to traditional concrete structures while maintaining impermeability to water, even at joints.
Implementation Method 1
Foam blocks, optionally fiber wrapped, are disposed between inner and outer layers of the panel
Implementation Method 2
outer fiber-reinforced polymeric layer, the outer layer comprising a first set of fibers in a first reaction-cured resin composition
Data Source
AI summary
Light weight fiber-reinforced polymeric structural building panels and methods; sized, configured for fabrication of non-portable wall structures permanently fixed to natural base. The panel main body, and studs, can be fabricated separately, then assembled to each other to complete panel fabrication. Methods for making the main body are hand lay-up, or pultrusion. Studs are typically pultruded, and subsequently prepared having consistent thickness, flat surface, across the width of the stud end wall which is to be mounted to the main body. Foam blocks are between inner and outer layers of the panel. Foam blocks can be prepared in block clusters before assembly to the main body. In the main body, a fibrous layer is between each pair of next adjacent foam blocks. Intercostals extend “y” and “z” dimensions transverse to the length of the main body. Studs can be mounted to the main body using adhesive, mechanical fasteners, or both.