Prefabricated Wall Panels with Integrated Steel Connectors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional building skin systems for external wall panels are limited by weight, cost, and assembly time, often requiring additional structural members to comply with design code requirements, which increases weight and complexity.
Innovation Solution
A prefabricated building skin system comprising a composite external wall panel with a fiber-reinforced polymer wrapping around a foam core, integrated steel connectors, and thermoset resin, allowing for self-supporting, lightweight panels that can span between columns without additional structural members, and can be finished with various aesthetic options like brick or paint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional skin systems use additional structural members to satisfy code requirements, then the panels can meet design code requirements, but the weight of the external skin system increases
Solution Approach 1:
The patent combines multiple functions into a single integrated wall panel system. The composite panel integrates structural support, cladding, and code-compliance features (such as fire rating, insulation, and structural strength) into one unified component, eliminating the need for separate structural members while meeting all design code requirements.
Solution Approach 2:
The patent uses composite materials in the wall panel construction, combining different materials (such as concrete, steel reinforcement, insulation layers, and cladding materials) to create a multi-functional panel that achieves structural strength, thermal insulation, fire resistance, and aesthetic cladding functions simultaneously, thereby reducing overall weight while meeting code requirements.
2Strength
If traditional skin systems use additional structural members to support cladding, then the panels can react loads during assembly and service, but the complexity of the system increases
Solution Approach 1:
The patent merges the load-bearing structural function and the cladding function into a single integrated wall panel. The composite panel design incorporates structural reinforcement directly within the panel assembly, allowing it to react loads during assembly, transportation, installation, and service without requiring external structural members, thereby simplifying the overall system.
3Reliability
If traditional skin systems require multiple different components, then the panels can satisfy various design code requirements, but the assembly time increases
Solution Approach 1:
The patent applies preliminary action by pre-assembling and pre-integrating all necessary components (structural elements, insulation, cladding, and code-compliance features) into complete wall panels at the manufacturing site before transportation. This off-site prefabrication allows for quality control and code compliance verification to be completed beforehand, significantly reducing on-site assembly time while maintaining all required code standards.
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 solution provides a lightweight, cost-effective, and efficient building skin system that meets multiple design code requirements, reduces on-site labor and time, and allows for faster construction by prefabricating panels with integrated finishes and connections, enabling quicker building occupancy.
Implementation Method 1
a thermoset resin may be infused into the composite external wall panel
Implementation Method 2
the fiber reinforced polymer may be wrapped around a panel edge connecting the inner skin and the outer skin
Data Source
AI summary
Apparatus, systems, and methods for a prefabricated building skin system including a composite external wall panel. The external wall panel may include an inner skin forming a first side of the external wall panel and an outer skin forming a second side of the external wall panel. A fiber reinforced polymer is wrapped around a panel edge connecting the inner skin and the outer skin. A foam center may be disposed between the inner skin and the outer skin. A thermoset resin may be infused into the composite external wall panel. At least one steel connector integrated between the inner skin and the outer skin. The steel connector may be connectable to a building column, wherein the steel connector is configured to support a vertical load.