Multilayer Construction Panel with Bulges for Frame-Free Installation
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Solution Overview
Problem
Existing multilayer panels for construction surfaces require laborious installation, high precision frames, and skilled labor to achieve parallelism and are not impermeable to water and steam, leading to increased costs and time.
Innovation Solution
A multilayer panel comprising a first expanded plastic layer, a second impermeable layer, and a third layer with bulges that engage with the surface to ensure parallelism, allowing easy installation without frames and providing thermal insulation and impermeability to water and gases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a frame is used to fix the panel to the surface, then the panel can be installed, but the installation becomes laborious and time-consuming
Solution Approach 1:
The invention extracts and eliminates the frame from the installation system. The panel is designed to be fixed directly to the surface without requiring an intermediate frame structure, thereby simplifying the installation process and reducing labor time while maintaining the panel's stability and positioning functions
Solution Approach 2:
The invention merges the panel with the fixing function by integrating attachment means directly onto the panel. The panel combines insulation, waterproofing, and fixation functions in a single integrated component, eliminating the need for separate frame and fastening systems
2Manufacturing precision
If a frame is used to ensure parallelism, then parallelism can be achieved, but high dimensional accuracy is required which increases frame cost
Solution Approach 1:
The panel incorporates self-aligning features through its geometric design. The attachment means and panel configuration enable the panel to automatically establish parallelism with the surface during installation without requiring pre-manufactured precision frames, thereby reducing manufacturing costs while maintaining accuracy
Solution Approach 2:
The invention changes the approach to achieving parallelism by using geometric parameters of the panel and attachment means rather than relying on frame dimensional accuracy. The design uses inherent geometric relationships and installation geometry to ensure parallelism, shifting the precision requirement from manufacturing to installation geometry
3Manufacturing precision
If experienced personnel install the frame and panel, then parallelism is guaranteed, but installation costs increase
Solution Approach 1:
The panel design incorporates self-aligning and self-positioning features that guide installation without requiring specialized skills. The geometric configuration of attachment means and panel edges provides natural alignment cues, enabling unskilled personnel to achieve correct parallelism through the design itself rather than through expert judgment and adjustment
4Reliability
If conventional multilayer panels are used, then coverage is provided, but they are not impermeable to water and steam
Solution Approach 1:
The panel uses composite material construction with an expanded plastic material core combined with waterproofing layers. This composite structure integrates thermal insulation and waterproofing functions into a single panel system, achieving water and steam impermeability without significantly increasing structural complexity
Solution Approach 2:
The panel is designed as a multi-functional element that simultaneously provides thermal insulation, waterproofing, steam barrier, and structural support. By consolidating multiple functions into a single panel assembly, the invention achieves reliable protection against water and steam while avoiding the need for additional separate layers or components
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 panel achieves quick, cost-effective installation with perfect parallelism and impermeability to water and gases, reducing installation time and skill requirements while enhancing thermal insulation.
Implementation Method 1
the first layer has a thermal conductivity comprised between 0.02 and 0.035 W/mK; the panel according to the invention, thanks to this reduced thermal conductivity, is therefore a good thermal insulator
Implementation Method 2
a second layer, impermeable or substantially impermeable to water and steam
Implementation Method 3
a third layer, fixed, directly or indirectly, to the first layer on the side opposite to the second layer, and comprising a plurality of first bulges, spaced apart from each other so as to define an air channel between them
Data Source
AI summary
A panel for the construction industry suitable for being fixed to cover a surface of a building structure, the panel including a first layer including an expanded plastic material, a second layer, impermeable or substantially impermeable to water and steam, fixed, directly or indirectly, to the first layer, a third layer, fixed, directly or indirectly, to the first layer on the side opposite to the second layer, and including a plurality of first bulges, spaced apart from each other so as to define an air channel between them, and having the same height.