Precast Concrete Panel Structure With Insulating Core and Load Strength

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Solution Overview

Problem

Traditional on-site construction methods face challenges such as non-availability of skilled labor, heavy machinery, project delays, poor quality, and lack of scalability, while existing precast modules fail to adequately address thermal insulation and structural strength requirements, leading to energy inefficiency and discomfort in buildings.

Innovation Solution

A precast concrete panel design comprising a reinforced concrete first layer, a thermally insulating core, and a fiber-reinforced concrete second layer, with a lattice girder for load-bearing and connecting members, optimized for thermal performance and structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional on-site construction methods are used, then construction flexibility and customization are maintained, but skilled labor availability, project completion time, and construction quality deteriorate

Engineering Contradiction:

Improveconstruction flexibilityVSAvoidproject completion speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The building is divided into standardized precast modules that can be manufactured separately in controlled factory environments and then assembled on-site. This segmentation enables parallel production activities, improving project completion speed while maintaining design flexibility through modular configuration options.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Construction components are prepared in advance in factory settings with pre-installed insulation, reinforcement, and finishing elements. This preliminary action ensures consistent quality control and reduces on-site construction time, directly addressing the productivity deterioration associated with traditional methods.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If precast modules are used, then construction speed and quality consistency improve, but thermal insulation performance deteriorates

Engineering Contradiction:

Improveconstruction speedVSAvoidthermal insulation performance

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The precast modules utilize composite construction combining concrete layers with integrated thermal insulation materials. This composite approach maintains the structural integrity and construction speed benefits of precast modules while significantly improving thermal insulation performance to meet energy efficiency requirements.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Thermal insulation elements are strategically integrated into specific regions of the precast modules where heat transfer is most critical. This local quality enhancement ensures optimal thermal performance without compromising the overall construction speed and structural benefits of the precast system.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If precast modules are used, then construction repeatability and scalability improve, but structural strength and thermal insulation requirements are not adequately met

Engineering Contradiction:

Improveconstruction repeatabilityVSAvoidstructural strength

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The module design employs composite construction with reinforced concrete layers combined with structural insulation materials that meet both structural strength requirements and thermal insulation performance. This resolves the contradiction by achieving both repeatability and adequate structural/thermal performance.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The precast modules incorporate adjustable parameters such as insulation thickness, reinforcement density, and module dimensions that can be optimized to meet specific structural strength and thermal insulation requirements while maintaining construction repeatability and scalability across different building applications.

Inventive Principle:

Principle #35Parameter changes

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

Enhances energy efficiency, reduces heating and cooling costs, and maximizes indoor space by integrating thermal insulation and structural strength into precast panels, while ensuring consistent quality and speed in construction.

Implementation Method 1

a core having a thermally insulating material

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS20250347111A1Method and arrangement for forming precast concrete panels

Publication Date: 2025.11.13 ONX INC

AI summary

A precast concrete panel is described. The precast concrete panel includes a first layer forming a rear-side of the precast concrete panel, wherein the first layer has concrete with a reinforcement structure, a core having a thermally insulating material, and a second layer forming a front-side of the precast concrete panel, wherein the second layer has fiber reinforced concrete. Further, the first layer, the core, and the second layer are coupled to each other to form the precast concrete panel.