Precast Concrete Panel Connector for Manual Assembly
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Solution Overview
Problem
Existing building construction methods using concrete blocks are time-consuming and weak due to mortar joints, while smaller concrete panels require heavy machinery and complex reinforcement, necessitating improved precast concrete panel systems and methods.
Innovation Solution
A concrete panel system with specific connector structures and reinforcing bar placement methods that allow for robust connections between panels, eliminating the need for internal reinforcement and heavy machinery, using lightweight materials and adaptable panel designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If concrete blocks are used for building walls, then construction is easily done manually, but the process is time-consuming and the product has many weak mortar joints
Solution Approach 1:
The wall structure is segmented into discrete precast concrete panels that can be manufactured separately and then assembled on-site. This segmentation allows for parallel production of multiple panels, significantly increasing construction productivity while maintaining manual assembly feasibility through the use of lightweight panel dimensions and simple connector-based joining methods.
2Productivity
If concrete panels are used to eliminate mortar joints, then construction speed improves, but the panels become massive and require heavy machinery for assembly
Solution Approach 1:
The panel design incorporates segmentation through the use of standardized modular dimensions and integrated connector systems that divide the panel into manageable sections. This allows panels to be large enough to eliminate mortar joints and improve construction speed, yet small and lightweight enough to be manually positioned and assembled without heavy machinery.
3Ease of operation
If smaller concrete panels are used for manual handling, then assembly becomes easier, but structural reinforcement within the panel is required, complicating manufacturing
Solution Approach 1:
The reinforcement function is extracted from the panel body and relocated to external connector elements. The panels themselves are designed as simple, unreinforced concrete slabs that are easy to manufacture, while the structural strengthening is provided by separate connector components that attach to the panel edges, eliminating the need for complex internal reinforcement during panel manufacturing.
4Ease of manufacture
If traditional mortar joints are used between panels, then assembly is simple, but the joints are inherently weak and cannot resist wind and earthquake forces
Solution Approach 1:
The joint system uses a composite construction combining precast concrete panels with metal connector elements. The connectors act as a different material phase that provides superior mechanical strength and structural performance compared to traditional mortar, while the assembly process remains simple through the standardized connector interface that guides panel placement and secures connections without requiring complex procedures.
Data Source
AI summary
A concrete panel system includes first, second, and third rectangular precast concrete panels, each defining a respective top edge, bottom edge, and first and second lateral edges. A first type connector is formed in the concrete material at least along the top edge of the first panel and along the first lateral edge of the first panel. A second type connector is formed in the concrete material at least along the second lateral edge of the second panel, and along the bottom edge of the third panel. The first type connector and the second type connector are configured to connect together so as to form a cavity between the respective panel edges. This cavity extends along the first lateral edge of the first panel to facilitate positioning rebar between adjacent panels.