Layered Insulated Wall Panel With Glass-Fiber Cement Core
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Solution Overview
Problem
Existing brick construction materials are labor-intensive to install and require skilled labor, making them costly, and there is a need for improved insulation in building materials, especially for retrofit applications.
Innovation Solution
A wall panel comprising a glass-fiber reinforced cementitious middle layer with an attached insulation layer and a veneer layer, which can be easily installed and provides improved insulation, using a method that includes pouring a cementitious slurry, embedding glass fibers, and applying a foam insulation layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional brick is used for exterior surfaces, then thermal resistance and structural strength are improved, but installation labor intensity and cost increase
Solution Approach 1:
The wall panel is divided into distinct functional layers: a structural cementitious layer with glass fiber reinforcement, an insulation layer with foam material, and a veneer layer with brick-like appearance. This segmentation allows each layer to be optimized independently and installed as a pre-assembled unit, eliminating the need for skilled brick masons while maintaining thermal resistance and structural strength.
Solution Approach 2:
The panel uses composite materials combining cementitious products with glass fiber reinforcement for structural integrity, foam materials for insulation, and veneer materials for aesthetic appearance. This composite approach achieves the thermal resistance of traditional brick construction while dramatically reducing installation labor requirements through factory pre-assembly.
2Strength
If traditional brick construction is used, then structural strength and aesthetic appeal are improved, but installation time and labor cost increase
Solution Approach 1:
The structural cementitious layer, insulation layer, and veneer layer are assembled into complete wall panels in the factory before delivery to the construction site. This preliminary action allows the panels to be installed as ready-to-assemble units, dramatically reducing on-site installation time while maintaining structural strength through the reinforced cementitious core.
3Loss of energy
If insulation performance is improved in building materials, then energy efficiency is improved, but material complexity and manufacturing difficulty increase
Solution Approach 1:
The insulation layer is merged with the structural cementitious layer and veneer layer into a single integrated wall panel assembly. This merging combines the functions of structure, insulation, and aesthetics into one manufacturable unit, improving energy efficiency through the foam insulation while managing manufacturing complexity through standardized production processes.
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 solution reduces installation labor requirements and costs while providing superior insulation, allowing for easy retrofitting and maintaining aesthetic appeal, with the glass-fiber reinforcing material acting as the principal load carrier.
Implementation Method 1
applying, to the second side of the cured cementitious product, an insulation layer, the insulation layer comprising a foam
Implementation Method 2
forming a glass-fiber reinforced cementitious layer which includes the steps of: i) pouring or injecting a slurry of uncured cementitious product into a mold, ii) embedding glass fiber reinforcing material therein
Data Source
AI summary
The invention is related to a method of manufacturing a wall panel and a wall panel system. The method includes forming a glass-fiber reinforced cementitious layer including the steps of: pouring or injecting a slurry of uncured cementitious product into a mold, embedding glass fiber reinforcing material therein, and curing the cementitious product to obtain a cured cementitious product having a first side and a second side; and applying, to the second side of the cured cementitious product, an insulation layer, the insulation layer comprising a foam.