Prefabricated Wall Panel With High-Density Foam Binder
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Solution Overview
Problem
Current prefabricated panels for building wall coverings are cumbersome due to their large size and weight, making them difficult to handle and install, especially outdoors where wind resistance adds to the challenge, and they often require significant modifications to supports for proper installation around doors and windows.
Innovation Solution
A prefabricated panel design with a reduced thickness of less than 40 mm, achieved by using a high-density polyurethane foam binder layer (greater than 150 kg/m³) and a flexible silicone template to maintain panel flatness and rigidity, allowing for easier handling and installation without excessive support modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the panel thickness is increased to prevent breaking during transport and handling, then the panel strength and rigidity are improved, but the panel weight and difficulty of handling increase significantly
Solution Approach 1:
The patent changes the density parameter of the polyurethane foam binder layer from conventional low density (30-60 kg/m³) to high density (greater than 150 kg/m³). This parameter change allows the binder layer to provide sufficient structural strength and rigidity with reduced thickness, thereby reducing overall panel weight while maintaining strength requirements for transport and handling.
Solution Approach 2:
The patent uses a composite structure combining rigid outer plates (terracotta, ceramic, concrete, stone) with a high-density polyurethane foam binder layer. This composite material approach allows the lightweight foam to provide structural support while the rigid plates provide the necessary surface strength, achieving optimal strength-to-weight ratio.
2Ease of operation
If the panel thickness is reduced to facilitate handling and reduce weight, then the ease of operation is improved, but the panel rigidity and flatness may deteriorate
Solution Approach 1:
By increasing the density parameter of the polyurethane foam to greater than 150 kg/m³, the patent achieves higher compressive strength and rigidity in a thinner layer. This allows the panel to maintain sufficient rigidity for installation while being thin enough (less than 40 mm) to handle easily and fit in spaces with limited clearance.
3Volume of moving object
If the panel thickness is reduced to minimize space loss during indoor installation, then the loss of space is reduced, but the panel may become more susceptible to breaking during transport
Solution Approach 1:
The high density (greater than 150 kg/m³) of the polyurethane foam binder layer provides enhanced mechanical strength and impact resistance, allowing the panel to be thin (reducing volume and space loss) while maintaining reliability during transport and handling.
Solution Approach 2:
The combination of rigid outer plates with the high-density polyurethane foam creates a composite structure where the foam acts as a shock-absorbing core, protecting the brittle outer plates from breaking during transport while keeping the overall panel thickness minimal.
4Length of stationary object
If the binder layer density is increased to reduce thickness, then the panel thickness is reduced, but the manufacturing complexity may increase
Solution Approach 1:
The patent specifies using high-density polyurethane foam (greater than 150 kg/m³) which, while a denser material, follows the same basic injection molding process as conventional foams. The main manufacturing step is injecting the liquid polyurethane mixture into the mold cavity between the outer plates, where it expands and cures to form the binder layer. This process is similar to conventional foam manufacturing but requires control of foam expansion to achieve the desired high density.
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
The reduced thickness and weight of the panels facilitate easier handling and installation, enabling their use both indoors and outdoors without significant space loss or support modifications, while maintaining structural integrity and flatness.
Implementation Method 1
an inner layer, arranged in contact with the rear face of the outer layer, and constituting a binder layer for the wafers. The binder layer is a polyurethane foam
Data Source
Figure 1~3
Figure 4~5
Figure 6
AI summary
The panel (1) has an outer layer (3) formed of splits (7) made up of clay, ceramic, concrete or stone, where the splits are spaced apart from each other and arranged in rows. An inner layer (5) e.g. polyurethane foam, is placed in contact with a rear part of the outer layer and forms a binding layer for the splits. The inner layer presents density of 150 kilograms/cubic meter at liquid state before foaming to reduce total thickness of the panel below 40 millimeter. The foam is composed of a mixture of polyol and isocyanate. Independent claims are also included for the following: (1) a conformator comprising a jig for fabricating a panel (2) a method for fabricating a panel.