Integrated Wall Panel With Extended Post For Modular Construction
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Solution Overview
Problem
Existing wall systems for acoustic barriers and retaining walls require separate installation of posts and panels, leading to increased construction time, cost, and potential structural instability due to unbalanced stresses and shifting, especially on uneven terrain.
Innovation Solution
An integrated post and panel module with extended top and bottom portions that accommodate terrain changes and provide support, allowing for a single operation installation and reduced stress transfer, featuring a panel portion integrally formed with a post portion, including a groove for adjacent modules and a caisson or pier for enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate installation of posts and panels is used, then structural stability can be achieved, but construction time and cost increase
Solution Approach 1:
The patent combines the post and panel into a single integrated module where the post is an extended integral portion of the panel. This merging eliminates the need for separate installation operations, reducing construction time while maintaining structural stability through the integrated design that ensures proper alignment and connection.
2Length of stationary object
If extended posts are used for tall walls, then wall height and stability are improved, but cost and complexity of anchoring increase
Solution Approach 1:
The post is merged with the panel as an integral extended portion, eliminating the need for separate anchoring systems with flanges, bolts, and concrete encapsulation. The integrated design simplifies the anchoring process while providing the necessary post length for tall wall applications.
3Ease of manufacture
If standardized wall panels are used, then manufacturing efficiency is improved, but adaptability to uneven terrain decreases
Solution Approach 1:
The integrated post extends beyond the standard panel height, providing adjustable length to accommodate varying terrain conditions. This dynamic adaptation allows standardized panels to be used while achieving the necessary wall height and alignment on uneven ground, maintaining both manufacturing efficiency and terrain adaptability.
Data Source
AI summary
A wall module for a modular wall structure integrates a wall panel portion with a post portion having top or upper and bottom or lower extensions and at least one groove for receiving a distal end portion of a wall panel portion of an adjacent module. The bottom/lower extension is set within an exposed portion of a reinforcing cage of a caisson or pier extending below grade and the reinforcing cage and bottom/lower extension are encapsulated with a material such as concrete to integrate the caisson or pier with the bottom/lower post extension. Alternatively, the bottom post extension can be formed to have a length sufficient to support the module in soil and a pier or caisson integrally formed therewith by pouring concrete around the bottom post extension within a post hole.