Prefabricated Composite Panel Building with Rigid Frame
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Solution Overview
Problem
Conventional building structures are expensive, labor-intensive, and time-consuming to erect due to the need for numerous individual components and complex assembly processes, which increases costs and reduces efficiency.
Innovation Solution
A building design that combines a single, rigid beam-and-post frame unit with standard, modular, rectangular wall and roof panels, where the beam-and-post frame unit is secured to a concrete foundation, providing the primary structural support for the assembly of prefabricated panels, reducing the need for extensive labor and materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional building structures use numerous individual posts and beams assembled to form a frame structure, then structural integrity is achieved, but construction cost and labor intensity increase significantly
Solution Approach 1:
The patent combines multiple individual posts and beams into a single integrated post-and-beam frame unit. This frame unit is formed as one piece or pre-assembled module that replaces numerous separate components, thereby maintaining structural integrity while significantly reducing the number of parts that need to be handled and assembled on-site.
Solution Approach 2:
The building structure is segmented into modular components: a single frame unit, prefabricated wall panels, and roof panels. This segmentation allows the complex frame structure to be simplified into a manageable single unit that can be easily transported and installed, while the building envelope is divided into separate panels that can be assembled around the frame.
2Volume of stationary object
If conventional building structures use thousands of individual pieces assembled on site, then complete building enclosure is achieved, but construction time and labor requirements increase
Solution Approach 1:
The frame unit, wall panels, and roof panels are all prefabricated off-site before delivery to the construction location. The frame unit is prepared in advance as a complete structural module, and the panels are manufactured with their final shapes and connections pre-formed, enabling rapid on-site assembly without extensive cutting or fabrication work.
Solution Approach 2:
Multiple building components (frame, walls, roof) are combined into a simplified assembly process where a single frame unit supports prefabricated panels that interlock or attach directly to it. This merging of functions into fewer components dramatically reduces the number of assembly steps and labor hours required to complete the building enclosure.
3Strength
If conventional building structures use numerous individual pieces and complex assembly processes, then structural completeness is achieved, but material cost per volume enclosed increases
Solution Approach 1:
The consolidation of multiple frame members into a single frame unit reduces the total amount of material required for the structural frame. By eliminating redundant connections, joints, and overlapping components, the design uses less material while maintaining the same load-bearing capacity and structural integrity, thereby reducing material cost per volume enclosed.
Solution Approach 2:
The invention changes the structural parameter from numerous small components to a single integrated frame unit with optimized dimensions and geometry. This parameter change allows the structure to achieve the required strength with less total material volume, improving material efficiency and reducing costs.
Data Source
AI summary
A building structure (100) is erected on a concrete slab (105). The structure comprises a rigid beam-and-post frame (110) and a plurality of wall and roof panels (130, 145). A first end of the posts (120) of the frame are secured to the concrete slab. A beam (115) is secured to a second end of the posts. Adjacent wall and roof panels are secured to one-another by interlocking edges joined with adhesive or other fasteners. Wall panels adjacent to the posts of the frame may be secured to the posts. Roof panels are secured to the beam and wall panels. Wall panels are secured to the concrete slab by adhesive sealant (1000), angles (1005), and bolts (1010, 1015). Ceiling panels are secured to the beam by a plurality of bolts (1010), and brackets (1005, 1200). Openings (135) for windows and doors are formed in the wall panels.