Pre-insulated Structural Panels with Embedded C-Channels
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Solution Overview
Problem
Current building construction methods using pre-manufactured panels face challenges with limited features for installation efficiency, acoustical dampening, and structural integrity, often requiring multiple components and increasing installation time and costs.
Innovation Solution
Pre-insulated structural panels with embedded vertical c-channels and EPS foam, featuring tongue-and-groove edges for easy assembly, horizontal and vertical chases for wiring, and fastening plates for enhanced structural strength and acoustical dampening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple small building components are used to create vertical wall height, then flexibility in wall configuration is improved, but installation time and costs increase
Solution Approach 1:
The patent combines multiple small building components into a single large pre-insulated panel that integrates structural support members, insulation material, and wiring chases. This merging reduces the number of separate components needed to achieve the same wall height and configuration, thereby decreasing installation time while maintaining adaptability through the panel's integrated design features.
Solution Approach 2:
The panel is pre-assembled with vertical support members embedded in insulation material, and wiring chases are pre-formed during manufacturing. This preliminary action of preparing the complete wall section before delivery to the construction site eliminates the need for on-site assembly of multiple components, reducing installation time while preserving configuration flexibility through standardized panel dimensions and attachment features.
2Productivity
If pre-manufactured building panels are used, then construction efficiency is improved, but features for installation efficiency and acoustical dampening are limited
Solution Approach 1:
The pre-insulated panel is designed to perform multiple functions simultaneously: it provides thermal insulation through the insulation material, structural support through embedded vertical support members, wiring integration through horizontal and vertical chases, and acoustical dampening through the insulated construction. This multi-functionality increases construction efficiency while providing diverse installation features without requiring separate components.
Solution Approach 2:
The panel incorporates segmented features including horizontal chases for lateral wiring runs and vertical chases for vertical wiring paths, allowing wiring to be routed in different directions within the same panel. This segmentation provides installation flexibility and adaptability while maintaining the panel's role as a single pre-manufactured unit that improves construction efficiency.
3Strength
If current building components are used, then basic structural function is achieved, but structural integrity and acoustical dampening are limited
Solution Approach 1:
The panel uses a composite construction combining rigid insulation material with embedded vertical support members made of structural material. This composite structure provides enhanced structural integrity compared to solid insulation panels, as the support members reinforce the insulation material. The acoustical dampening is improved by the composite construction that creates sound barriers through the combination of materials with different acoustic properties.
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 reduces installation time and costs while providing improved structural integrity and acoustical performance by allowing for efficient assembly and wiring integration within the panels, enhancing the overall building wall system.
Implementation Method 1
The EPS material may provide thermal insulating properties to a degree related to the thickness of the EPS panel
Data Source
AI summary
An apparatus and method for constructing pre-insulated structural panels is disclosed that has a tongue and groove assembly arrangement. Each panel may include one or more c-channels or profiles embedded in expandable polystyrene (EPS) foam to provide structural integrity to the panels, and resulting wall. The panels may be covered with siding, stucco, or similar materials. A chase may be formed horizontally in the panels to provide a wiring conduit through the panel. The panel may also provide when assembled, a vertical chase formed between the mated panels along the length of the panel for wiring. Acoustical properties may be formed in the surface of the EPS portions to provided added acoustical damping measures.