Positioning Element for Prefabricated Building Alignment
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Solution Overview
Problem
The panel construction method for residential and commercial buildings faces challenges in precise alignment and dimensional accuracy of prefabricated concrete parts, particularly due to mortar joint thickness variations and cracking issues caused by the weight of wall panels compressing the mortar bed.
Innovation Solution
A positioning element with two positioning projections and a flat spacer plate is used to maintain the desired mortar bed thickness, ensuring precise alignment and preventing cracking by keeping the wall panel off the ceiling, allowing the mortar bed to maintain its intended thickness and compensating for shrinkage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wall panels are placed directly on ceiling panels using mortar bed, then assembly is simple, but mortar joint thickness becomes inconsistent and cracks appear due to panel weight compressing the mortar
Solution Approach 1:
The positioning element acts as an intermediary component between the ceiling panel and wall panel. It includes a positioning projection that fits into a receptacle on the ceiling panel, and a spacer element that maintains a fixed distance between the ceiling panel and wall panel, preventing direct contact and ensuring consistent mortar joint thickness throughout the assembly process
Solution Approach 2:
The spacer element in the positioning element has a predetermined height that directly determines the mortar joint thickness. By changing the height parameter of the spacer element, the mortar joint thickness can be precisely controlled and maintained constant, regardless of the weight of the wall panel or variations in mortar bed application
2Loss of substance
If mortar bed thickness is reduced to minimize material use, then material consumption decreases, but dimensional accuracy is lost and cracks develop under panel weight
Solution Approach 1:
The positioning element with its spacer element serves as a mechanical intermediary that physically prevents the wall panel from compressing the mortar bed. The spacer maintains a fixed gap that ensures the mortar joint retains its intended thickness and dimensional accuracy, even when using minimal mortar material
Solution Approach 2:
The positioning element is installed on the ceiling panel before the wall panel is placed. This preliminary positioning ensures that when the wall panel is installed, the mortar joint thickness is already predetermined and maintained by the spacer element, preventing compression and cracking from the outset
3Device complexity
If positioning is done manually without fixtures, then device complexity is low, but positioning precision and alignment accuracy are insufficient
Solution Approach 1:
The positioning element with its positioning projection and receptacle acts as a mechanical intermediary that enables precise alignment. The projection fits into the receptacle with tight tolerance, automatically establishing correct horizontal and vertical alignment between ceiling and wall panels without requiring complex positioning equipment or skilled manual operation
Solution Approach 2:
The positioning element provides self-aligning functionality through its geometric design. The positioning projection and receptacle are designed with specific shapes and tolerances that guide the wall panel into the correct position automatically during installation, eliminating the need for external positioning devices or complex adjustment procedures
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
This solution enables efficient and precise alignment of building parts, maintaining the desired mortar joint thickness and minimizing cracking by using a flexible, high-density plastic positioning element that compensates for the weight-induced shrinkage of the mortar bed.
Implementation Method 1
the two positioning projections act together with the corresponding recordings of the building parts in the manner of a gauge
Implementation Method 2
A preferably flat spacer plate, which keeps the two parts of the building at a distance, extends in the transverse direction between these two
Implementation Method 3
the plastic material is flexible enough that it is squeezed together under the weight of the wall panel 2 lying on it in the area of the spacer plate 11, so that the wall panel 2 remains in contact with the mortar bed 12 over its entire surface. This minimizes cracking in the building unit
Data Source
Figure 1~2
Figure 3~5
AI summary
The positioning element has two averted positioning extensions (8,9) inserted in admissions (3,4) of building parts (1,2). A spacer plate (11) extending in transverse direction between the two positioning extensions is provided as intermediate layer between both building parts. The two positioning extensions have a truncated cone shaped design (10). An independent claim is also included for a building unit of positioning elements.