Prefabricated Sandwich Wall Module for Watertight Curtain Walls
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Solution Overview
Problem
Existing curtain wall systems fail to meet the requirements of the UNI EN 13830 standard, lacking structural stability, load-bearing capacity, and failing to accommodate building deformations, while also not ensuring water and air tightness, thermal insulation, sound insulation, fire resistance, and seismic protection.
Innovation Solution
A prefabricated module comprising a sandwich panel with edge profiles and gaskets, designed for easy assembly, which provides structural stability, load transfer, and incorporates features for thermal insulation, soundproofing, fire resistance, and seismic resilience, while maintaining water and air tightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional curtain wall systems are used, then assembly is simple, but structural stability and load-bearing capacity are insufficient
Solution Approach 1:
The curtain wall system is divided into modular units, each comprising a sandwich panel with integrated edge profiles and gaskets. This segmentation allows pre-assembly of complex structural components that ensure stability while maintaining ease of installation through modular replacement rather than whole-system complexity.
Solution Approach 2:
Multiple functional elements are merged into a single integrated module: the sandwich panel provides insulation and structural core, edge profiles provide mechanical connection and structural reinforcement, and gaskets provide sealing. This merging creates a compact unit that achieves high structural stability without requiring complex assembly of separate components.
2Reliability
If conventional curtain wall systems are used, then installation is straightforward, but water and air tightness are not ensured
Solution Approach 1:
Elastic gaskets are integrated into the edge profiles of sandwich panels. These flexible sealing elements deform to accommodate manufacturing tolerances and assembly variations, ensuring continuous water and air tightness seals without requiring precision alignment or complex sealing mechanisms.
Solution Approach 2:
The module combines different materials with complementary properties: metal or composite sandwich panels for structural integrity, rubber or polymer gaskets for elastic sealing, and interlocking profile systems for mechanical connection. This composite approach ensures reliable tightness while maintaining straightforward assembly through material compatibility.
3Reliability
If basic curtain wall systems are used, then manufacturing is simple, but thermal insulation and sound insulation are insufficient
Solution Approach 1:
Sandwich panels are manufactured with insulating core materials (such as foam or mineral wool) between outer skins, creating a composite structure that provides both structural strength and high thermal insulation in a single manufactured component. This eliminates the need for separate insulation layers and reduces manufacturing steps.
Solution Approach 2:
Thermal insulation, sound insulation, and structural functions are merged into the sandwich panel core and skin construction. The multi-layer composite structure naturally provides thermal breaks and acoustic damping while maintaining load-bearing capacity, achieving high insulation performance through integrated material design rather than added components.
4Reliability
If standard curtain wall systems are used, then maintenance is conventional, but seismic protection and fire resistance are not achieved
Solution Approach 1:
The module incorporates movable or adjustable connection elements between sandwich panels and the building structure, allowing the facade to dynamically accommodate seismic movements and thermal expansions. This dynamic capability provides earthquake resistance without requiring complex bracing systems or rigid constraints.
Solution Approach 2:
The system uses materials and connection details with modified parameters for fire resistance: fire-retardant treatments on metal profiles, intumescent coatings, or fire-resistant insulation materials in the sandwich panels. These parameter changes enhance fire safety while maintaining the overall modular structure without adding significant complexity.
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 module meets the UNI EN 13830 standard by ensuring structural stability, load transfer, and providing effective insulation, soundproofing, fire resistance, and seismic protection, while facilitating easy maintenance and assembly.
Implementation Method 1
at least one gasket (7a, 7b) of elastic material mounted within a respective seat (4a, 4b) of a respective profile (3) of the panel (2)
Data Source
AI summary
The present invention relates to a prefabricated or pre-assembled module for obtaining an external wall for cladding buildings or for obtaining a curtain wall, including:at least one sandwich panel,at least one edge profile,at least one gasket.