Pourable Foam Building Module with Cabling

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Solution Overview

Problem

Existing building materials and methods lack the combination of increased strength, durability, and safety while minimizing waste and production time, particularly in prefabricated structures, and do not effectively utilize pourable polyurethane foam or cabling for improved movability and seismic requirements.

Innovation Solution

A building framework utilizing pourable structural polyurethane foam with cabling for enhanced strength, thermal performance, and seismic resistance, where the foam is poured into cells to form a monolithic structure with improved tensile, compressive, and wind loading strength, and cabling is used for securing and lifting components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If spray or injection methods are used to apply polyurethane foam, then the foam can be applied quickly, but waste and overspray occur requiring expensive filtration equipment

Engineering Contradiction:

Improvefoam application speedVSAvoidfoam waste

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The foam application is segmented into controlled pours into individual cells rather than continuous spray or injection, allowing precise control of foam placement and eliminating overspray waste

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Cells formed by partition beams serve as intermediaries to contain and guide the foam, directing it precisely where needed without spray drift or uncontrolled expansion

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If spray or injection methods are used to apply polyurethane foam, then the foam can be applied quickly, but air pockets and uneven distribution occur

Engineering Contradiction:

Improvefoam application speedVSAvoidfoam distribution uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

Dividing the application into separate cell compartments allows each cell to be filled independently, ensuring uniform distribution and eliminating air pockets that occur in continuous spray methods

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The foam self-levels within each cell compartment due to gravity and controlled pouring, eliminating the need for additional equipment to ensure even distribution

Inventive Principle:

Principle #25Self-service

3Strength

If traditional building materials are used, then structural strength can be achieved, but weight increases reducing movability

Engineering Contradiction:

Improvestructural strengthVSAvoidbuilding component weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The combination of frame structure with partition beams and poured foam creates a composite material system that achieves structural strength while maintaining lightweight properties for improved movability

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Changing from traditional heavy building materials to a foam-based composite structure alters the density parameter while maintaining structural integrity through the frame reinforcement

Inventive Principle:

Principle #35Parameter changes

4Loss of time

If prefabricated building methods are used, then production time can be reduced, but strength and durability are compromised

Engineering Contradiction:

Improveproduction timeVSAvoidbuilding strength

Core Design Contradiction:

Loss of timeVSStrength

Solution Approach 1:

The frame structure with partition beams is prepared in advance as a prefabricated component, allowing rapid assembly while the poured foam cures to provide the required structural strength

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The composite construction of frame and foam provides both rapid prefabrication capability and enhanced structural strength, overcoming the traditional trade-off between speed and durability

Inventive Principle:

Principle #40Composite materials

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 solution provides increased strength, thermal performance, and seismic resistance, reduces waste and production time, and eliminates the need for expensive filtration equipment, while allowing for self-leveling and air pocket elimination in the foam application, and enhances safety during handling and assembly.

Implementation Method 1

pourable polyurethane foam that can be used as a structural polyurethane foam for floors, walls, and roof assemblies

Methodology Applied

Scientific EffectPolyurethane foam expansion and curing: Phase Change

Implementation Method 2

thermal performance

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS10683661B2Building module with pourable foam and cable

Publication Date: 2020.06.16 BIGELOW WILLIAM H

AI summary

A building component utilizing a pourable polyurethane or structural foam that can be used for floors, walls, and roof assemblies with a frame with an interior, back or a front, multiple partition beams forming cells in said frame, pourable polyurethane or structural foam exterior backing attached to said frame back. The structural foam is poured into said cells to a desired level, and after said structural foam is poured into said cells, said interior backing is attached to said frame front. Cabling is used to improve movability of the invention, and improve on wind loading and seismic requirements of the present invention. Safety is also improved during the manufacturing process, loading, unloading, and in final assembly through the use of cabling.