Lightweight Core Wall Structure With Mineral Board Webs
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Solution Overview
Problem
Conventional building technologies face challenges in combining structural and thermal elements efficiently, leading to increased costs, labor, and logistical constraints, while steel reinforcement in concrete structures is prone to corrosion and cracking, affecting durability and weight.
Innovation Solution
A core wall structure comprising lightweight thermal insulation material and mineral board webs, embedded in cement-based plaster skins, with reinforcement elements like steel rods or basalt fibers, providing structural integrity and thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If steel reinforcement is spaced from the underside of concrete structures to protect against corrosion, then reliability is improved, but weight and cost increase due to additional concrete coverage
Solution Approach 1:
The patent extracts the non-functional concrete from the tension zone below the steel reinforcement, removing only the necessary amount to eliminate harmful effects while preserving essential functions. This allows steel to be positioned closer to the underside, reducing overall concrete coverage and structure weight while maintaining corrosion protection through alternative means.
Solution Approach 2:
The patent changes the coverage parameter from conventional minimum coverage distances to reduced coverage distances, optimizing the balance between corrosion protection and weight reduction. By adjusting this parameter and using complementary protection methods, the structure achieves reliability without excessive concrete coverage.
2Reliability
If concrete is provided below steel reinforcement to protect against corrosion, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent removes excess concrete from the tension zone that does not contribute to structural strength, thereby reducing material costs and simplifying the manufacturing process while maintaining adequate corrosion protection through optimized reinforcement placement and alternative protective measures.
Solution Approach 2:
The patent optimizes the concrete coverage parameter to reduce material consumption and manufacturing cost while maintaining reliability through adjusted reinforcement positioning and complementary protection strategies.
3Reliability
If conventional building technologies use separate thermal insulation and structural elements, then functional requirements are met, but device complexity and construction time increase
Solution Approach 1:
The patent merges thermal insulation elements with structural wall elements into an integrated assembly, where insulation is positioned within the wall structure itself rather than as separate added layers. This integration reduces device complexity, shortens construction time, and maintains both thermal and structural functions in a unified system.
Solution Approach 2:
The patent creates multi-functional building elements that simultaneously provide structural support and thermal insulation, eliminating the need for separate components and reducing overall construction complexity while meeting all functional requirements.
4Device complexity
If pre-manufactured building modules are used to combine structural and thermal elements, then device complexity is reduced, but design freedom and extendibility are limited
Solution Approach 1:
The patent segments the wall structure into modular components (structural elements, insulation elements, panels) that can be independently designed, manufactured, and assembled. This segmentation enables both construction simplicity through standardization and design freedom through flexible combination and configuration of modules for different building requirements.
Solution Approach 2:
The patent develops universal building components that can serve multiple functions and be adapted to various design requirements, maintaining construction simplicity while enabling design freedom and extendibility across different building types and scales.
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 enhances structural strength, reduces weight, and improves thermal performance, enabling cost-effective and durable construction suitable for various building types, including high-rise structures.
Implementation Method 1
elements of lightweight thermal insulation material
Implementation Method 2
skins of cement-based plaster extending on the opposing outer surfaces of the core wall structure
Data Source
AI summary
A core wall structure is assembled by attaching together elements of lightweight thermal insulation material (16) and elements of mineral board (20), positioned between them to serve as webs (20) at spaced intervals. Opposing edges (22) of the webs (20) are exposed on outer surfaces (26,28) of the core wall structure, with recesses (24) around them. Skins (18) of cement-based plaster are applied to the outer surfaces (26,28) to cover the core wall structure at least in part and to embed the exposed edges (22) of the webs (20) at least in part in the cement-based plaster.