Prefabricated Wall Panel With Hollow Tubes And U-Shape Beams
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Solution Overview
Problem
Existing prefabricated wall panel technologies face challenges in reducing construction time, labor, and costs while maintaining construction quality, particularly in efficiently assembling and reinforcing building structures on-site.
Innovation Solution
The proposed solution involves a prefabricated wall panel design featuring hollow tubes with flanges, U-shape beams, and slings for rebar insertion, along with integrated insulation and electrical components, allowing for efficient assembly and reinforcement, reducing on-site labor and enhancing structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional prefabricated wall panels are used with concrete blocks and insulation, then construction can be done offsite and transported to the construction site, but the assembly process requires significant on-site labor and time for positioning and reinforcing
Solution Approach 1:
The wall panel is divided into modular components including pre-positioned hollow tubes, U-shape beams, and separate reinforcement elements that can be independently manufactured and then quickly assembled on-site. This segmentation allows for efficient offsite production while enabling rapid on-site configuration and assembly.
Solution Approach 2:
The hollow tubes are pre-positioned within the wall panel structure during offsite manufacturing, and the U-shape beams are pre-configured with attachment mechanisms. This preliminary preparation eliminates the need for complex on-site positioning operations, significantly reducing assembly time and labor requirements while maintaining manufacturing efficiency.
2Strength
If steel rebars are added to reinforce wall panels and provide interlocking, then structural strength is improved, but the complexity of assembly and reinforcement processes increases
Solution Approach 1:
The hollow tubes serve multiple functions simultaneously: they provide structural reinforcement, act as interlocking elements between adjacent wall panels, and serve as conduits for electrical wiring. The U-shape beams combine structural support with attachment points for both wall panels and ceiling panels. This merging of functions reduces the number of separate components and simplifies the overall assembly process while maintaining enhanced structural strength.
Solution Approach 2:
The hollow tubes are designed to perform multiple roles including reinforcement, interlocking, and electrical conduit functions. The U-shape beams serve as both structural supports and attachment mechanisms for various panel types. This multi-functionality reduces assembly complexity by eliminating the need for separate dedicated components for each function.
3Manufacturing precision
If more reinforcement elements and integrated components are added to wall panels, then construction quality and structural integrity are improved, but the manufacturing time and cost increase
Solution Approach 1:
The reinforcement elements and integrated components are manufactured as separate pre-fabricated components rather than being monolithic. This allows for specialized manufacturing processes optimized for each component type, improving quality through precision manufacturing while reducing overall manufacturing time through parallel production processes.
Solution Approach 2:
All reinforcement elements, hollow tubes, and integrated components are pre-manufactured and pre-positioned during offsite production. This preliminary action allows for quality control and precision manufacturing in a controlled industrial environment, while the actual assembly is rapidly completed on-site, effectively reducing the critical path duration of the construction project.
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 design enables faster and more efficient construction with reduced labor costs, improved structural strength, and enhanced quality by allowing for quicker assembly and integration of insulation and electrical components, thus addressing the inefficiencies of traditional methods.
Implementation Method 1
The flange is welded to the periphery of the each tube
Data Source
AI summary
A building apparatus for a residential or commercial building that includes a prefabricated wall panel and a horizontal beam mounted on a top of the prefabricated wall panel. The prefabricated wall panel includes a first concrete block, a second concrete block, and an insulation panel sandwiched between the two concrete blocks. A plurality of spaced-apart hollow tubes extend between the top side and the bottom side of the prefabricated wall panel and each tube has a flange at its a periphery. The tubes reinforce the first concrete block, and the flanges are supported on the top side of the wall. The horizontal beam is fastened to these flanges. The prefabricated wall panel further includes a U-shape beam that extends from the top side to the bottom side and is positioned at or near the left side or the right side of the prefabricated wall panel. A plurality of slings spaced apart run along a length of the U-shape beam and can provide for assembling two wall panels.