Integrated Rigid Foam Panel with Embedded Reinforcement
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Solution Overview
Problem
Existing building wall assembly methods are time-consuming and costly due to the need for multiple steps and components, particularly when incorporating insulation and structural reinforcement.
Innovation Solution
A planar panel made of cured rigid foam with integrated reinforcement, featuring continuous recesses for windows and doors, and a frame-like reinforcement unit that encircles these recesses, allowing for efficient assembly and enhanced load-bearing and thermal insulation capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple separate components (insulation layer, reinforcement, wall panels) are used to form a building wall, then each component can be optimized independently, but the assembly process becomes time-consuming and costly
Solution Approach 1:
The patent combines multiple previously separate components (insulation layer, reinforcement elements, and wall panels) into a single integrated planar panel. The reinforcement is embedded within the rigid foam insulation during manufacturing, creating a unified structure that eliminates the need for separate assembly steps, thereby reducing assembly time and cost while maintaining the functional benefits of each individual component
Solution Approach 2:
The planar panel serves multiple functions simultaneously: it provides thermal insulation through the rigid foam, structural reinforcement through the embedded reinforcement elements, and wall formation through its planar structure. This multi-functional design allows a single component to replace what previously required multiple separate components and assembly operations
2Ease of operation
If recesses for windows and doors are created in the wall body, then accessibility and sunlight incidence are improved, but the structural strength and load-bearing capacity are reduced
Solution Approach 1:
The reinforcement units are pre-positioned and embedded within the rigid foam insulation during the manufacturing process, specifically located adjacent to recess areas. This preliminary placement ensures that reinforcement is already in position before the panel is installed, allowing recesses to be created without compromising structural integrity, as the reinforcement provides necessary support around opening areas
Solution Approach 2:
The patent creates a composite structure by embedding reinforcement elements (metal, glass fiber, or basalt fiber) within the rigid foam insulation material. This composite construction provides both the insulation properties of the foam and the structural strength of the reinforcement, allowing recesses to be formed while maintaining load-bearing capacity through the reinforced composite structure
Data Source
Figure 1~2
AI summary
The invention relates to a planar panel (2) for forming a wall of a building, comprising at least one wall body (4) formed from a hardened rigid foam and comprising at least one reinforcement (6) arranged within the hardened rigid foam and comprising at least one reinforcement element (8) formed entirely or at least partially from a filament yarn textile.