Prefabricated Wall Element Vertical Assembly Foam Bonding
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Solution Overview
Problem
Current methods for manufacturing prefab building elements are time-consuming, labor-intensive, and costly, limiting their industrial application due to the need for extensive curing times and handling of freshly produced panels, which are prone to damage.
Innovation Solution
A method involving the vertical positioning of a fully cured concrete first wall part and the construction of a second wall part with a cavity in between, filled with an essentially liquid foam insulation material to bond and provide structural integrity, potentially using mechanical joining elements and a brick-laying robot for enhanced efficiency and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If horizontal mould method is used with mortar spraying, then bricks can be bonded together to form wall parts, but the process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent inverts the conventional horizontal mould process by using vertical positioning of wall parts. Instead of spraying mortar horizontally and assembling panels later, the method vertically positions complete wall parts and fills cavities with expanding foam insulation material, which simultaneously provides bonding and insulation functions, thereby reducing manufacturing time and labor requirements
Solution Approach 2:
The patent merges multiple functions into the foam insulation material: it provides thermal insulation, bonds the first and second wall parts together, and fills the cavity space. This consolidation eliminates the need for separate bonding materials and reduces the number of manufacturing steps, improving both ease of manufacture and productivity
2Productivity
If freshly produced panels are handled and rotated during horizontal production, then assembly can proceed, but the panels are prone to damage due to incomplete curing
Solution Approach 1:
The patent inverts the production orientation from horizontal to vertical. Wall parts are positioned vertically during assembly rather than being handled horizontally, which reduces gravitational stress and handling damage risks on freshly produced panels with incomplete curing
Solution Approach 2:
The first wall part is pre-cured to full strength before assembly, providing a stable base that can support the weight of subsequent elements without requiring the intermediate panels to be fully cured. This preliminary action ensures structural reliability during the assembly process
3Strength
If additional bonding materials and mechanical joining elements are used, then structural integrity is enhanced, but material usage and costs increase
Solution Approach 1:
The patent combines the bonding function with the insulation material. The expanding foam serves dual purposes: providing thermal insulation and bonding the wall parts together through mechanical interlocking and adhesive properties. This eliminates or reduces the need for separate bonding materials and mechanical joining elements, reducing material usage while maintaining structural integrity
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 method reduces production time, minimizes material usage, enhances structural integrity, and eliminates the need for additional bonding materials, resulting in a more cost-effective and durable prefab building element with improved insulation properties and reduced risk of damage during handling.
Implementation Method 1
The insulation material typically expands after application due to a chemical reaction with the surrounding air and water, to fill up the cavity between the wall parts
Implementation Method 2
Because the foam insulation material is provided in an essentially liquid state, the material will provide a good adhesion with the first wall part and the second wall part
Data Source
Figure 1A~1C
Figure 2A~2C
Figure 3
AI summary
The present invention relates to a method for manufacturing a prefab building element, comprising the steps of providing a first wall part made of concrete, vertically positioning the first wall part, building a masonry wall forming a second wall part at a predetermined distance from the first wall part, thus forming a cavity in between said first wall part and said second wall part, bonding the first wall part and the second wall part by filling the cavity with an essentially liquid foam insulation material, preferably an expandable foam insulation material.