Metallic Core Building Panels with Bridging Members
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current construction methods are prone to damage and structural integrity loss during extreme weather conditions due to delamination of external claddings and roofings, and the lightweight, corrugated nature of modular building systems makes them vulnerable to severe weather forces, leading to partial or total loss of structures.
Innovation Solution
A building system featuring a substantially metallic, solid, and continuous core member with thermally insulating and water-resistant sheathing members on either side, coupled by bridging members, which provides enhanced structural integrity and resistance to thermal expansion and oxidation, while allowing for insulation in voids between the core and sheathing members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If timber or steel stud and batten frame with external cladding is used, then construction is conventional and familiar, but the cladding is prone to lifting and tearing in extreme weather conditions resulting in loss of structural integrity
Solution Approach 1:
The building system divides the wall structure into discrete panel units, each comprising a rigid core with integrated cladding. This segmentation allows each panel to be independently engineered to resist weather forces, and the modular nature enables systematic installation with proper sealing and bracing throughout the structure.
Solution Approach 2:
The wall panels utilize composite construction combining a rigid core (metal studs with rigid insulation) and external cladding (fiber cement or similar weather-resistant material). This composite structure creates a unified assembly where the core provides structural strength and the cladding provides weather resistance, preventing delamination by integrating both functions into a single robust unit.
2Reliability
If sheet or tile roofing systems fastened by screws, bolts, or adhesives are used, then roofing can be installed conventionally, but the roofing is prone to delamination or separation from the structure exposing internal sections to damage
Solution Approach 1:
The roofing system merges the roofing material with the structural framework by integrating the roof cladding directly onto the roof panels and trusses. This creates a unified structure where the roofing and structural elements work together as a single system, eliminating the separation issues that occur with conventional multi-layer roofing assemblies.
Solution Approach 2:
The roofing panels and trusses are pre-assembled into complete roof sections with all attachments and sealings performed before installation. This preliminary assembly ensures proper integration of roofing materials with the structural framework, and allows quality control to verify attachment integrity before the roof is exposed to extreme weather conditions.
3Productivity
If pre-cast concrete or tilt-panel slab lift technology is used, then construction speed may be improved, but the structures experience fundamental degradation of integrity over prolonged period due to steel reinforcement, heat resistance, rapid cooling issues
Solution Approach 1:
The system divides the building into modular panels that can be rapidly assembled, achieving construction speed similar to pre-cast methods. However, unlike pre-cast concrete, each panel uses lightweight materials (metal studs with rigid insulation) that avoid the durability problems of steel reinforcement and thermal shock, while maintaining fast assembly through modular design.
Solution Approach 2:
The invention changes the material parameters from heavy pre-cast concrete to lightweight metal and insulation combinations. This parameter change maintains the rapid construction advantage while eliminating the durability issues associated with concrete curing, thermal expansion, and steel reinforcement corrosion over time.
4Ease of manufacture
If corrugated light gauge steel cores bolted together are used, then modular construction is achieved, but the lightweight nature renders the system vulnerable to extreme weather conditions
Solution Approach 1:
The wall panels utilize composite construction combining a rigid core (metal studs with rigid insulation) and external cladding (fiber cement or similar weather-resistant material). This composite structure creates a unified assembly where the core provides structural strength and the cladding provides weather resistance, preventing delamination by integrating both functions into a single robust unit.
5Weight of moving object
If large apertures are provided in building panel cores to keep panels lightweight, then panel weight is reduced, but the strength and structural integrity of the panels is reduced rendering them unsuitable for withstanding extreme conditions
Solution Approach 1:
The panel design applies local quality by providing rigid insulation and structural support at critical locations (around apertures and at panel edges) rather than uniformly throughout. This allows apertures to be positioned where needed for utilities while maintaining structural integrity at load-bearing locations, achieving both lightweight construction and weather resistance.
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 system significantly reduces the risk of structural damage from extreme weather conditions, maintaining structural integrity by preventing delamination and enhancing durability, thus minimizing the risk of partial or total loss of structures.
Implementation Method 1
a thermally insulating and water resistant sheathing member provided either side of said core member
Implementation Method 2
a thermally insulating and water resistant sheathing member provided either side of said core member
Data Source
AI summary
A building element (10) comprises a substantially metallic, substantially planar core member (20) and a thermally insulating and water resistant sheathing member (30) either side of the core member. The core member is continuous along a substantial length of the building element and a void (40) is created between the core member and at least one of the sheathing members. At least one bridging member (50) is provided in the void and couples the core member and at least one of the sheathing members. A building system and method of construction are also disclosed.