Reinforced Layer Molding for Foam-Filled Building Elements
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Solution Overview
Problem
Existing methods for manufacturing building construction elements, such as sandwich structures with polyurethane or polyisocyanurate, often result in air pockets and defects like sink marks, and are not suitable for fast production or fireproofing.
Innovation Solution
A method involving molding layers with parallel plates connected by reinforcement elements, injecting PUR or PIR foam between them, and adding additional layers with perpendicular reinforcement structures to reduce air pockets and defects, allowing for faster production and fireproofing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sandwich structures are produced by using a large block of foam and cutting it into pieces, then the production process is simple, but air pockets are created in the construction when pieces are glued together
Solution Approach 1:
The construction element is divided into multiple layers, each containing foam pieces arranged in a grid pattern. This segmentation allows the foam to be cut into smaller pieces that fit together without creating air pockets, while maintaining the simplicity of the production process through standardized cutting and assembly procedures.
Solution Approach 2:
Multiple layers of foam pieces are nested between outer plates, with each layer containing a grid of foam segments. This nested arrangement ensures that foam pieces are tightly packed without gaps, eliminating air pockets while maintaining ease of manufacture through systematic layering.
2Length of stationary object
If thick pieces are produced in a mold, then the construction element achieves desired thickness, but defects such as sink marks appear in the molded parts
Solution Approach 1:
Instead of producing a single thick molded piece, the construction element uses multiple thinner foam pieces arranged in layers. Each piece is molded separately, avoiding sink marks, and then assembled to achieve the desired overall thickness. This segmentation eliminates defects while maintaining the required thickness.
Solution Approach 2:
Foam pieces are pre-cut and pre-formed into grid patterns before being placed in the mold. This preliminary preparation ensures that the foam is ready for precise assembly without requiring complex molding operations that could create sink marks, thereby maintaining manufacturing precision while achieving desired thickness.
3Productivity
If traditional sandwich structures are manufactured, then the basic construction function is achieved, but the production process is not fast enough and fireproofing is difficult
Solution Approach 1:
The mold is prepared in advance with plates and reinforcement elements positioned to create the final construction element directly. This preliminary setup enables fast manufacturing by eliminating the need for subsequent assembly operations, while the integrated design facilitates fireproofing through standardized fire-resistant materials and construction methods.
Solution Approach 2:
Multiple functions are merged into a single molding process: the formation of foam pieces, their arrangement in grid patterns, and their assembly between plates all occur simultaneously in the mold. This merging dramatically increases productivity while the integrated structure incorporates fireproofing features as part of the standard manufacturing process.
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 method reduces air pockets and defects, enabling higher-quality construction elements with reduced layer thickness and tolerance, suitable for rapid manufacturing and fireproofing.
Implementation Method 1
injecting PUR or PIR into the space between the plates
Implementation Method 2
after a cooling process
Data Source
AI summary
Methods for manufacturing building construction elements, such as walls or horizontal divisions, are disclosed. An exemplary method comprises: a) molding a first layer by arranging in a first mold two parallel spaced apart plates, wherein a plurality of reinforcement elements extend between and connect the spaced apart plates; b) injecting foam polymer into the space between the plates; c) after a cooling process, either placing in the first mold a second layer comprising a plate member and a plurality of reinforcement structures or placing the first layer in a second mold and arranging a second layer comprising a plate member and a plurality of reinforcement structures into the second mold such that the reinforcement structures of the second layer bear against a plate of the first layer; d) injecting foam polymer into the space between the plate member of the second layer and the adjacent plate of the first layer.