Modular Insulated Concrete Wall Panels for Faster Precast Assembly
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Solution Overview
Problem
Conventional construction methods for concrete walls require lengthy curing times, necessitate additional steps for insulation and framing, and are labor-intensive, leading to increased costs and time consumption.
Innovation Solution
A modular insulated concrete wall panel system comprising precast concrete panels with interlocking insulation panels, where concrete is poured around preformed insulation panels to form rib elements, eliminating the need for on-site trades and reducing assembly time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional pour-in-place foundations are used, then the foundation can be formed with traditional methods, but the curing time of about 7 days delays subsequent construction stages
Solution Approach 1:
The foundation panels are precast off-site with insulation already integrated, eliminating the need for on-site curing. The panels are manufactured in advance and delivered ready for immediate installation, bypassing the 7-day curing delay inherent in conventional pour-in-place methods
Solution Approach 2:
The foundation panel integrates multiple functions into a single component: structural concrete base, insulation layer, and rib elements for wall attachment. This consolidation eliminates sequential construction steps and reduces overall time while maintaining manufacturing ease
2Reliability
If separate insulation and framing steps are added to concrete walls, then the walls gain thermal performance and interior space, but the construction becomes labor intensive and time consuming
Solution Approach 1:
The insulation is permanently integrated into the foundation panel structure during manufacturing, creating a single composite component. This eliminates the need for separate insulation installation and framing steps on-site, reducing labor intensity and construction time while maintaining thermal performance
Solution Approach 2:
The foundation panel combines concrete, insulation materials, and structural rib elements into a composite structure with optimized properties. The concrete provides structural strength, the insulation provides thermal performance, and the integrated design maintains construction efficiency
3Productivity
If precast concrete panels with integrated insulation are used, then installation time is reduced and construction is accelerated, but the system complexity increases
Solution Approach 1:
The foundation system is divided into modular precast panels that can be manufactured independently and assembled on-site. Each panel is a self-contained unit with standardized dimensions and integrated features, simplifying the complex task of building entire foundation sections while maintaining high installation speed through modular assembly
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 allows for quicker installation, reduces material weight by 30%, meets energy efficiency standards, and provides improved weather resistance and noise protection, while minimizing labor and time requirements.
Implementation Method 1
The inside of a concrete wall will also require insulation and/or framing to provide a useable interior space
Implementation Method 2
provides improved weather resistance and noise protection
Data Source
AI summary
The present invention provides a modular insulated concrete wall panel system comprising at least one assembled panel, each assembled panel comprising a precast concrete panel and one or more insulation panels. The concrete panel has an outer frame and plurality of vertical ribs that engage with corresponding channels on the insulation panels. There is also provided a method of forming a modular concrete wall panel system of the present invention, comprising the steps of: providing the at least one preformed insulating panel laid horizontally with the vertical channels facing in an upward direction; pouring concrete around the at least one preformed insulating panel such that the concrete fills the channels in the insulating panel, thereby forming the concrete panel rib elements; and allowing the concrete panel to set and cure.