Interlocking Panel Assemblies With Utility Routing and Fire Resistance
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Solution Overview
Problem
Structural Insulated Panels (SIPs) face issues with durability, corrosion resistance, difficulty in incorporating mechanical, electrical, and plumbing lines, and inadequate fire safety ratings, while intermodal shipping containers offer limited building configuration options.
Innovation Solution
A multi-purpose structural panel member made from extruded aluminum or other materials, featuring interior channels for insulation and ventilation, with male and female interlocking components, tracks for alignment, and channels for line routing, along with auxiliary components like corner and frame members for efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If Structural Insulated Panels (SIPs) are used for construction, then insulation performance is improved, but durability and corrosion resistance deteriorate due to delamination in poor conditions
Solution Approach 1:
The patent employs a composite panel structure consisting of two metal veneers (such as aluminum or steel) bonded to opposite faces of a foam core (such as expanded polystyrene or polyurethane). This composite construction provides both thermal insulation and structural durability, with the metal veneers protecting the foam core from moisture and physical damage while maintaining insulation performance.
Solution Approach 2:
The patent specifies that the metal veneers should have a minimum thickness (e.g., at least 0.019 inches or 0.023 inches) and the foam core should have specific density ranges (e.g., 1.5 to 2.0 pounds per cubic foot). These parameter specifications ensure that the panel achieves both adequate insulation performance and resistance to delamination under various environmental conditions.
2Loss of energy
If SIPs are used for construction, then insulation performance is improved, but ease of operation deteriorates due to difficulty in running mechanical, electrical, or plumbing lines
Solution Approach 1:
The patent incorporates predetermined channels or cavities within the foam core of the SIP panel. These segmented pathways are designed to accommodate mechanical, electrical, and plumbing lines, allowing utilities to be routed through the panel thickness without compromising the insulation performance or requiring extensive cutting and modification of the panel structure.
3Loss of energy
If SIPs are used for construction, then insulation performance is improved, but fire safety deteriorates due to inadequate fire safety ratings
Solution Approach 1:
The patent specifies that the metal veneers (such as steel or aluminum) provide a fire-resistant barrier that protects the foam core from direct exposure to fire. The metal facing layers act as a shield, slowing down heat transfer to the combustible foam material and providing time for evacuation or fire response, thereby improving the overall fire safety rating of the panel assembly.
4Strength
If intermodal shipping containers are used for construction, then structural strength is improved, but adaptability deteriorates due to limited building configuration options
Solution Approach 1:
The patent employs modular SIP panels that can be cut, sized, and configured to various specifications. These segmented panels can be assembled in different arrangements (such as rectangular, L-shaped, or custom geometries) to create diverse building configurations, unlike fixed-size shipping containers. The panels maintain structural strength while offering flexibility in design and layout.
Solution Approach 2:
The patent allows for adjustable and reconfigurable panel assemblies that can be modified during construction or even after completion. The connection systems and framing methods enable dynamic reconfiguration of the building structure, allowing owners to change interior layouts, add rooms, or adapt the building to new uses, providing ongoing adaptability that rigid container structures cannot match.
Data Source
AI summary
The present invention is directed to a system for construction using multi-purpose panel member, which may be utilized as any surface or support beam in a structure, along with auxiliary components including track members and corner members. In a preferred embodiment, the track member includes one or more channels for receiving panel members, and may also accommodate fasteners for securing the panel member to the track member. The corner member may be used to adjoin two or more panels at a desired angle, and may also serve as a decorative cap for the interconnection of two or more panel members.