Nesting J-Shaped Panels for Fire-Resistant Wall Structures
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Solution Overview
Problem
Existing building and wall construction systems lack effective fire retardant performance, particularly in applications requiring high fire resistance, as they do not adequately address the need for comprehensive fire protection across structures.
Innovation Solution
The construction of wall and roof structures using multiple layers of panels with J-shaped configurations, where the ends of each panel nest to form studs, and are secured with fasteners and reinforcing members, with seams staggered between layers to enhance stability and fire resistance, allowing for the use of materials like galvannealed steel and gypsum drywall.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple wall structures are joined to form buildings with panels having J-shaped configurations that nest to form studs, then fire resistance is improved (achieving four-hour, three-hour, and one-and-a-half-hour fire ratings), but device complexity increases due to multiple layers, staggered seams, reinforcing members, and fasteners
Solution Approach 1:
The wall structure is divided into multiple layers of panels with J-shaped configurations that nest to form studs. Each layer is independently constructed but collectively provides enhanced fire resistance through the segmented multi-layer design, where seams are staggered between layers to prevent fire propagation.
Solution Approach 2:
Panels with J-shaped ends are nested together to form stud structures. The J-shaped configurations of adjacent panels interlock, with one panel's J-end fitting within the configuration of another panel, creating a nested assembly that forms the structural stud without requiring separate stud components.
2Ease of manufacture
If panels with J-shaped configurations are used to form studs through nesting, then manufacturing ease is improved by eliminating separate stud production, but device complexity increases due to the specialized J-shaped panel configurations
Solution Approach 1:
The panel serves multiple functions: it acts as both the wall covering and the structural stud component. The J-shaped configuration enables the panel to form studs through nesting, eliminating the need for separate stud manufacturing while maintaining structural integrity. This multi-functional design simplifies the overall manufacturing process.
Solution Approach 2:
The panel and stud are merged into a single integrated component. Instead of using separate panels and studs, the J-shaped panel configuration allows the panel itself to form the stud structure when nested with other panels, combining two previously separate elements into one.
Data Source
AI summary
A wall structure includes first and second panels joined to form a stud and a first wall layer. A fastener extends through the first wall layer and into the stud. Each panel includes first and a second ends. The first end of one panel and the second end of the other panel form a portion of the stud. The ends of the panels can nest. The wall structure can include multiple wall layers arranged such that the seams formed by components of each wall layer are staggered with respect to the seams in adjacent wall layers. Reinforcing members and fasteners can secure the wall layers to the remainder of the structure. A similarly constructed roof structure can be joined with multiple wall structures to form a building.