Modular Infill Wall Panel with Top Hat Reinforcement
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Solution Overview
Problem
Existing metal sub-frame systems for multi-storey building construction are expensive to manufacture and install, prone to on-site detailing errors, and time-consuming, necessitating a more cost-effective and error-resistant wall system with improved mechanical characteristics.
Innovation Solution
A structural infill wall panel module comprising composite insulating panels with profiled connection parts, external and internal reinforcing elements, and a flexible seal system, which interengage to form a strong and airtight joint without the need for secondary framing, allowing for easy assembly and reduced on-site errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal sub-frame systems are used for external walls, then mechanical strength and structural stability are improved, but manufacturing cost and installation time increase significantly
Solution Approach 1:
The wall system is divided into modular panels that can be manufactured independently and then assembled on-site. Each panel is a self-contained unit with integrated insulation, cladding, and structural elements, eliminating the need for time-consuming metal sub-frame assembly while maintaining structural integrity through the modular design
Solution Approach 2:
Multiple functions are combined into a single integrated panel structure. The panel merges structural support, thermal insulation, weatherproofing cladding, and internal lining into one unified component, eliminating the need for separate metal sub-frames and reducing installation time while maintaining mechanical strength
2Stability of the object's composition
If metal sub-frame systems are used for external walls, then structural stability is improved, but manufacturing cost increases
Solution Approach 1:
The panel uses composite construction combining insulating materials (such as foam or fiber), cladding materials (such as metal or composite panels), and structural elements in a single integrated unit. This composite approach provides structural stability while reducing manufacturing cost by eliminating the need for expensive metal sub-frames
Solution Approach 2:
The panels are pre-manufactured with all structural, insulating, and cladding components already assembled and integrated during factory production. This preliminary action ensures structural stability is achieved through controlled manufacturing processes while reducing on-site construction costs and time
3Strength
If metal sub-frame systems are used for external walls, then mechanical characteristics are improved, but on-site detailing errors and workmanship problems increase
Solution Approach 1:
By dividing the wall system into discrete modular panels with standardized connection interfaces, the design eliminates the complexity of metal sub-frame assembly and reduces on-site detailing errors. Each panel is a self-contained unit that can be installed reliably without requiring skilled metal framing workmanship
Solution Approach 2:
The panels are designed to be self-sufficient units that include their own structural support, insulation, and cladding components. This self-service design eliminates the need for complex metal sub-frame assembly and reduces reliance on skilled workmanship, thereby improving installation reliability
Data Source
AI summary
A facade/wall system comprises a number of modules. Each module comprises a plurality of insulating panels which have connection means on opposite sides thereof for interengaging the panels together at joints between the panels. Reinforcing elements in the form of top hat sections bridge the joints between adjacent panels. The top hat reinforcement elements used to interconnect adjacent panels in a module ensure that the composite panels act together as monolithic structure that creates a diaphragm while providing a surface to which cladding can be fixed and also providing a cavity between the panels and the cladding attached to the modules. They stiffen the panels and thereby enhance resistance to deflection. The system is cost effective and relatively easy and quick to install.