Load-Bearing Insulated Prefabricated Element
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Solution Overview
Problem
Conventional prefabricated insulated panels in construction are not load-bearing, suffer from movement and cracking issues, and are limited in their ability to accommodate various exterior coverings, requiring additional intermediary materials like wooden slats for fixing, which restricts flexibility and ventilation.
Innovation Solution
A load-bearing prefabricated element with a profile comprising a web and flanges, anchored by a branching system made of stainless steel or corrosion-resistant materials, allowing for the fixation of diverse facings and roofings, and incorporating polyurethane foam insulation for high thermal efficiency, ensuring airtightness and adaptability to different construction needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional prefabricated insulated panels are used, then insulation performance is improved, but load-bearing capability deteriorates
Solution Approach 1:
The patent merges the load-bearing concrete structure with the insulation layer into a single integrated prefabricated element. The concrete web and flanges provide structural strength while the polyurethane foam insulation is incorporated within the same element, eliminating the need for separate insulation panels and achieving both load-bearing capability and high thermal insulation performance simultaneously.
2Loss of energy
If insulated sandwich cladding panels are used, then insulation performance is improved, but structural stability deteriorates due to movements and cracks
Solution Approach 1:
By integrating the insulation layer within a monolithic concrete structure featuring a web and flanges, the patent creates a unified element that moves as one piece during thermal expansion or settlement. This eliminates the interface between separate panels that causes cracks and movements, while maintaining high insulation performance through the continuous polyurethane foam layer.
3Ease of operation
If wooden slats are used as intermediary for fixing covering, then fixing capability is improved, but adaptability to different coverings deteriorates
Solution Approach 1:
The patent incorporates multiple types of fixing means directly into the concrete structure, including U-shaped profiles for mechanical fixing, anchoring elements for secure attachment, and integrated mounting points. This universal fixing system can accommodate various covering types (tiles, slates, photovoltaic panels, membranes) without requiring different intermediary materials, eliminating the limitation of wooden slats while maintaining ease of installation.
4Device complexity
If conventional three-phase construction method is used, then construction simplicity is improved, but construction time deteriorates
Solution Approach 1:
The patent incorporates insulation, fixing means, and structural elements into a single pre-assembled prefabricated unit manufactured off-site. This preliminary action allows multiple construction steps to be completed during manufacturing, so that on-site installation only requires placing and securing the complete element, dramatically reducing construction time while maintaining process simplicity.
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 provides a load-bearing, highly insulated, and adaptable prefabricated element that can support various types of facings and roofings, ensuring airtightness and thermal efficiency, while eliminating the need for intermediary materials, thus addressing movement and cracking issues and enhancing construction flexibility.
Implementation Method 1
synthetic shoe having the function of reducing the phenomenon of thermal bridges
Implementation Method 2
layer of insulation 3... the anchoring element and the profile are made of stainless material or steel protected from corrosion and the insulating layer is made of polyurethane foam
Data Source
Figure 1(a)
Figure 1(b)
Figure 1(c)
AI summary
The element has an insulating layer (3) attached to a concrete shear wall (2), where the layer is made of polyurethane foam. The layer includes fixation units for assuring the indifferent fixation of any type of outer roofings or coverings (4) on a free surface of the layer and ensuring the transfer of loads from the roofings or coverings to the concrete shear wall. The fixation units include a U shaped section (6) arranged partially in the layer, an anchoring element (5) fixed to the section, and assembling elements (9) allowing the assembly of the roofings or coverings to the section. The roofings or coverings are claddings in wood, metal, parging, masonry, natural stone or paint, tiles, shingles, slates, photovoltaic panels, metal roofs or flat roof seals. An independent claim is also included for an air lock or closed carcass comprising an air seal.