Prefabricated Insulated Panels for Multi-Storey Building Construction
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Solution Overview
Problem
Conventional multi-storey building construction methods using prefabricated panels lack flexibility and optimization for specific applications, resulting in inadequate performance in terms of weight, structural strength, fire resistance, acoustic insulation, and temperature insulation, and are often resource-intensive and costly.
Innovation Solution
The use of prefabricated wall and floor panels with embedded cross-bracing, cementitious layers, and acoustic dampening cavities, along with cantilevered floor panels and water drainage channels in the roof profile, allows for customized properties and efficient assembly, addressing the need for varied performance characteristics and reduced construction time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional cast-in-place concrete construction methods are used, then structural strength and fire resistance are achieved, but construction time is extended due to curing requirements and resource consumption increases
Solution Approach 1:
The patent applies preliminary action by pre-casting concrete panels, columns, and beams in a controlled factory environment before transport to the construction site. These precast elements have already undergone curing and strength development, eliminating the need for extended on-site curing time. The panels are prepared in advance with embedded reinforcement and concrete finishes, allowing rapid assembly through mechanical connection rather than traditional formwork and pouring.
Solution Approach 2:
The building structure is segmented into discrete precast concrete panels, columns, and beams that can be independently manufactured and transported. Each panel is a self-contained structural unit that can be produced in parallel at the factory, then assembled on-site like modular components. This segmentation allows simultaneous production of multiple elements while the building takes shape through rapid assembly, dramatically reducing overall construction time compared to sequential cast-in-place methods.
2Strength
If conventional cast-in-place concrete construction is used, then structural integrity is ensured, but material cost and resource allocation increase significantly
Solution Approach 1:
Concrete panels and structural elements are pre-cast in a controlled factory environment where materials can be optimized and waste reduced. The factory setting allows for precise batching and placement of concrete and reinforcement, minimizing material waste compared to on-site pouring. Excess concrete can be recycled in the factory, and reinforcement steel can be precisely cut and positioned before concrete placement, reducing both material consumption and labor costs.
Solution Approach 2:
The patent merges multiple functions into single precast concrete panels, including structural load-bearing capacity, insulation layers, finishing surfaces, and embedded utilities. By combining these functions into integrated panels manufactured in a factory, the total material quantity required is reduced compared to traditional methods where each function would require separate materials and installation steps on-site.
3Ease of manufacture
If prefabricated panels with uniform properties are used, then manufacturing simplicity is maintained, but adaptability to specific application requirements is reduced
Solution Approach 1:
The patent applies local quality by customizing the properties of individual precast concrete panels according to their specific location and function within the building. Different panels can have varying concrete strengths, insulation thicknesses, reinforcement configurations, and dimensional specifications tailored to their particular requirements. For example, panels in high-stress load-bearing locations can be manufactured with higher concrete strength and additional reinforcement, while non-structural panels can use lighter formulations.
Solution Approach 2:
The manufacturing system allows for parameter changes in panel specifications based on application requirements. Concrete mix designs can be adjusted for different strength classes, insulation materials can be varied in thickness and type, reinforcement ratios can be modified, and panel dimensions can be customized. These parameter variations are accommodated in the factory production process, enabling each panel to be optimized for its specific function while maintaining the overall prefabricated construction approach.
4Productivity
If prefabricated panels are designed for modularity and universality, then assembly efficiency is improved, but flexibility for environmental adaptation is decreased
Solution Approach 1:
While maintaining a modular panel system for efficient assembly, the patent applies local quality by allowing customization of panel properties for different environmental conditions. Panels can be manufactured with specific insulation values, thermal bridge reductions, and material selections appropriate for their location (e.g., higher insulation for colder climates, enhanced fire resistance for specific zones). The standardized connection systems and panel dimensions preserve assembly efficiency, while the customizable internal properties provide environmental adaptation.
Solution Approach 2:
The patent achieves universality through standardized panel dimensions, connection details, and structural configurations that can be used across different building types and locations. This universal framework enables rapid assembly and interchangeability of panels. Simultaneously, the panels incorporate multi-functionality by integrating various performance characteristics (structural strength, thermal insulation, acoustic insulation, fire resistance) into each panel type, allowing the same modular system to adapt to different environmental requirements through material and design variations rather than requiring completely different panel systems.
Data Source
AI summary
Example systems and methods of constructing multi-storey buildings utilizing a plurality of prefabricated insulated panels, each prefabricated insulated panel comprising a first cementitious layer, a second cementitious layer, and an insulative core, wherein the insulative core is disposed between first and second cementitious layers. The systems and methods comprise constructing a building foundation and constructing a plurality of storeys on said foundation. Each storey may comprise a plurality of prefabricated insulated panels forming a load-bearing exterior wall disposed on an outer perimeter of the storey. Each storey may comprise a plurality of prefabricated insulated panels forming core walls, wherein the first and second cementitious layers of the core wall panels comprise a fire resistant material. Each storey may comprise a plurality of prefabricated insulated panels forming demising walls. Each storey may comprise a plurality of prefabricated insulated panels forming corridor walls. Each storey may comprise a plurality of prefabricated insulated panels forming a floor. The systems and methods further comprise constructing a roof on top of the last storey thereby constructed, the roof comprising a plurality of prefabricated roof panels.