Prefabricated Wall Panel Anchoring System
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Solution Overview
Problem
Prefabricated concrete panels with a natural stone visible face are prone to detachment and failure due to mortar detachment, especially at moderate heights, as they lack additional securing means suitable for their heterogeneous composition and geometry, leading to weak anchoring points.
Innovation Solution
Incorporating internal and external anchoring means, such as a wire geometry with inclined vertices embedded in the mortar layer and double body hooks, respectively, to provide secure support and minimize panel movement, allowing for flexible assembly and maintaining mortar thickness for enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If prefabricated panels are fixed solely with mortar, then the construction process is simple, but the panels are prone to detachment and failure, especially at moderate heights
Solution Approach 1:
The patent combines multiple anchoring methods (mortar fixation, mechanical anchors, and wire mesh reinforcement) into a unified system. The mechanical anchors are integrated directly into the panel structure during manufacturing, creating a composite anchoring system that merges chemical bonding (mortar) with mechanical interlocking (anchors), thereby resolving the contradiction between construction simplicity and anchoring reliability.
Solution Approach 2:
The patent employs composite anchoring materials and structures, including the combination of mortar (cementitious material) with metal mechanical anchors and wire mesh. This composite approach leverages the adhesive properties of mortar and the mechanical strength of metal components, achieving both ease of manufacture and high reliability simultaneously.
2Strength
If metal wires are used for anchoring in facades, then anchoring strength is improved, but the heterogeneous composition and geometry of prefabricated panels create weak areas where anchoring is not possible
Solution Approach 1:
The patent divides the anchoring system into multiple segments or components: mechanical anchors at specific locations, wire mesh covering broader areas, and mortar providing continuous bonding. This segmentation allows each component to address specific anchoring needs in different regions of the heterogeneous panel, overcoming the limitation of uniform anchoring approaches on non-uniform surfaces.
Solution Approach 2:
The patent applies different anchoring mechanisms to different locations on the panel based on local requirements. Mechanical anchors are placed at specific points where higher strength is needed, while wire mesh provides distributed reinforcement in areas with varying geometry. This localized approach ensures optimal anchoring performance across the entire heterogeneous panel surface.
3Reliability
If additional securing means are incorporated in the panel, then panel stability is improved, but the panel design and manufacturing complexity increases
Solution Approach 1:
The patent incorporates mechanical anchors and wire mesh into the panel structure during the manufacturing process, before the panel is installed. This preliminary integration of anchoring components eliminates the need for complex field assembly operations and reduces on-site construction complexity, while ensuring that the panel is pre-configured with optimized anchoring locations and configurations.
Data Source
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AI summary
The invention relates to a prefabricated panel for wall construction, of the type formed by a base layer and another stone layer or the like, defining the visible face (104), in which the layer forming the visible face [104] of the panel [1] has a plurality of blocks or slabs (3) on the base layer (102), attached to one another and occupying virtually the entire contour of the mold, with the desired format for the panels and the inside being tightly filled with said blocks or slabs (103).