Prefabricated Building Panels with Insulative Core and Embedded Elements

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Solution Overview

Problem

Existing prefabricated building panels are heavy, difficult to maneuver, and fail to provide the necessary performance characteristics, making them inefficient and costly for constructing buildings while also having a significant carbon footprint.

Innovation Solution

The development of non-load bearing and load-bearing prefabricated panels with an insulative core and embedded structural elements, designed for easy assembly and installation, which can be coupled to a building's structure for efficient construction and reduced resource usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If existing prefabricated panels are used, then construction speed is improved, but weight increases making them difficult to maneuver

Engineering Contradiction:

Improveconstruction speedVSAvoidpanel weight

Core Design Contradiction:

ProductivityVSWeight of moving object

Solution Approach 1:

The panel is divided into distinct functional layers: an insulative core layer for thermal insulation, a structural layer with embedded elements for strength and connection, and surface layers for finishing. This segmentation allows each layer to be optimized independently, reducing overall weight while maintaining structural integrity and insulation performance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The panel uses composite construction combining lightweight insulative materials (such as foam or fiber insulation) with cementitious or metal structural components. This composite approach provides both thermal insulation and structural strength without the excessive weight of traditional solid concrete panels, enabling easier handling and installation while meeting performance requirements.

Inventive Principle:

Principle #40Composite materials

2Loss of time

If existing prefabricated panels are used, then construction time is reduced, but structural strength and performance characteristics are insufficient

Engineering Contradiction:

Improveconstruction timeVSAvoidstructural strength

Core Design Contradiction:

Loss of timeVSStrength

Solution Approach 1:

Structural elements such as steel reinforcement bars, connection anchors, and insulation are pre-installed into the panel during manufacturing. This preliminary action ensures that when panels are assembled on-site, the structural integrity and performance characteristics are immediately achieved without requiring additional field operations, thus reducing construction time while guaranteeing strength requirements are met.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The panel design incorporates optimized material densities, thicknesses, and reinforcement configurations to achieve the minimum required structural strength while minimizing weight. By carefully controlling parameters such as insulation thickness, reinforcement spacing, and concrete density, the panel meets strength requirements without excessive material usage, enabling faster construction with adequate structural performance.

Inventive Principle:

Principle #35Parameter changes

3Loss of substance

If existing prefabricated panels are used, then resource usage is reduced, but ease of assembly and installation deteriorates

Engineering Contradiction:

Improvematerial usageVSAvoidease of assembly

Core Design Contradiction:

Loss of substanceVSEase of operation

Solution Approach 1:

The panel design incorporates standardized connection elements and interface features that can be used across different panel types and building configurations. Embedded structural elements serve multiple functions: providing structural strength, enabling mechanical connection between panels, and facilitating attachment to building frameworks. This multi-functionality reduces the number of separate components needed, simplifying assembly while minimizing material usage.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This solution allows for quicker and more efficient building construction with reduced material usage and carbon footprint, while providing improved structural strength and thermal insulation, and can be easily shipped and assembled on-site.

Implementation Method 1

prefabricated panels with an insulative core

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS20220403653A1Prefabricated building panels and methods for constructing buildings

Publication Date: 2022.12.22 NEXIICAN HOLDINGS INC

AI summary

Example embodiments of the described technology provide a prefabricated building panel. The prefabricated panel may comprise a rigid insulative core having first and second opposing surfaces. A first cementitious material may at least partially cover the first surface of the insulative core. A second cementitious material may at least partially cover the second surface of the insulative core. At least one embedded element may extend along a peripheral edge of the insulative core.