Hybrid Building Panels With 3D Cladding for Faster Envelope Assembly

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Traditional building construction using structural insulated panels (SIPs) is costly, labor-intensive, and time-consuming due to the need for additional layers and on-site finishing, which weakens the panels and increases construction time and costs.

Innovation Solution

A modular hybrid building panel system combining SIPs with customizable 3D-printed exterior cladding, panel connectors, and anchoring components, allowing for easy installation and forming a building envelope during construction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional SIPs are used with additional exterior cladding layers, then structural insulation and strength are improved, but construction time and labor costs increase

Engineering Contradiction:

Improvestructural strengthVSAvoidconstruction time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The patent combines the SIP core with exterior cladding into a single integrated hybrid building panel. The cladding is directly attached to the SIP skin, merging two separate components (SIP and cladding) into one unified element that provides both structural insulation and exterior finishing simultaneously, eliminating the need for sequential installation of separate layers.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The exterior cladding is pre-attached to the SIP in the factory before delivery to the construction site. This preliminary action of combining components off-site allows the panel to arrive as a ready-to-install unit with finished surfaces, eliminating on-site cladding installation and reducing construction time.

Inventive Principle:

Principle #10Preliminary action

2Strength

If additional exterior cladding layers are added to SIPs, then insulation and strength are improved, but labor requirements increase

Engineering Contradiction:

Improveultimate strengthVSAvoidlabor requirements

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The hybrid building panel merges the SIP core with pre-attached exterior cladding into a single integrated component. This consolidation reduces the number of separate installation tasks required on-site, as the cladding is already bonded to the SIP skin, thereby reducing labor requirements while maintaining structural strength.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cladding is pre-attached to the SIP in the factory before delivery to the construction site. This preliminary action of combining components off-site allows the panel to arrive as a ready-to-install unit with finished surfaces, eliminating on-site cladding installation and reducing construction time.

Inventive Principle:

Principle #10Preliminary action

3Shape

If SIPs are finished on-site with additional layers, then exterior cladding is achieved, but panel integrity is compromised due to penetrations

Engineering Contradiction:

Improveexterior claddingVSAvoidpanel integrity

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The hybrid building panel is designed as a segmented integrated unit where the cladding and SIP core are bonded together as one component. This segmentation approach allows the panel to be manufactured with complete exterior finishing in the factory, avoiding on-site penetrations that would compromise panel integrity.

Inventive Principle:

Principle #1Segmentation

4Use of energy by stationary object

If traditional SIP construction methods are used, then structural insulation is provided, but construction costs increase

Engineering Contradiction:

Improveinsulation valueVSAvoidconstruction system complexity

Core Design Contradiction:

Use of energy by stationary objectVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The hybrid building panel serves multiple functions simultaneously: it provides structural support, thermal insulation, and exterior cladding in a single integrated component. This multi-functionality reduces the overall complexity of the construction system by eliminating the need for separate installation of multiple components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20260022552A1Modular hybrid building panel systems

Publication Date: 2026.01.22 MIGHTY BUILDINGS INC

AI summary

A modular hybrid building panel system configured to form an envelope for an entire building or a portion thereof can include a plurality of hybrid building panels, a plurality of panel connectors, and a plurality of anchoring components. Each hybrid building panel can include at least a structural insulated panel coupled with a customizable 3D-printed exterior cladding. The plurality of panel connectors can be coupled to the plurality of hybrid building panels and can be configured to couple the plurality of hybrid building panels to each other horizontally, vertically, or both. The plurality of anchoring components can be coupled to the plurality of hybrid building panels and can be configured to couple the plurality of hybrid building panels to one or more separate building components.