Sandwich Panel Building Modules for Fast, Relocatable Construction
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Solution Overview
Problem
Prefabricated dwellings face limitations in design and assembly due to transportation constraints, and conventional timber-framed construction is labor-intensive and inefficient, while sandwich panels are underutilized in domestic buildings for their structural and cladding capabilities.
Innovation Solution
A building module comprising a sandwich panel with a thermoplastic skin and steel joists, designed with complementary profiles and ribbed structures, allowing for easy assembly and integration into a building structure using screw fixings and screw piles, enabling efficient construction and relocation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional timber-framed construction is used, then the building can be constructed using traditional methods, but the assembly process becomes labor-intensive and inefficient
Solution Approach 1:
The patent combines multiple functions into a single integrated sandwich panel structure. The panel integrates structural framing, insulation, and cladding into one monolithic component, eliminating the need for separate timber framing and insulation installation steps, thereby reducing labor intensity and improving assembly efficiency
Solution Approach 2:
The building is divided into modular sandwich panel sections that can be manufactured separately and assembled quickly on-site. Each panel is a self-contained module with standardized dimensions and integrated features, enabling rapid assembly without complex on-site construction processes
2Strength
If sandwich panels are used, then the structure provides integrated structural and cladding systems with high strength-to-weight ratio, but their use is less common in domestic buildings due to lack of familiarity
Solution Approach 1:
The sandwich panels are designed with locally optimized properties for domestic applications. The insulation core thickness and skin material selection are tailored to meet residential thermal performance requirements, while the structural strength is optimized for typical domestic load conditions, making the technology adaptable to home construction
Solution Approach 2:
The sandwich panel structure serves multiple functions simultaneously: it provides structural support, thermal insulation, weather protection, and aesthetic cladding. This multi-functionality makes it highly adaptable to domestic buildings where space and complexity need to be minimized
3Productivity
If prefabricated dwellings are transported to site, then construction can proceed independent of weather and travel, but the design is limited by transportation constraints on width, height, and length
Solution Approach 1:
The dwelling is segmented into multiple sandwich panel modules that can be transported within standard vehicle dimensions. These modules are designed to fit within transportation constraints while maintaining functional integrity, allowing flexible building configurations when assembled on-site
Solution Approach 2:
The design transitions from three-dimensional volumetric modules to two-dimensional panel assemblies that can be transported flat. This dimensional change allows greater design flexibility and larger building footprints while maintaining compatibility with standard transportation infrastructure
4Loss of time
If a multi-proof building consent is obtained, then the building consent application must be approved within 10 days, but this requires strict adherence to approved design specifications
Solution Approach 1:
The sandwich panel system is designed with pre-engineered, standardized components and assembly procedures that are submitted for multi-proof building consent approval in advance. This preliminary action establishes a certified construction framework that enables rapid permitting while maintaining design flexibility through standardized modular configurations
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A building module which is a sandwich panel comprising a first region which provides part of the roof structure of a building, a second region which provides part of the wall structure of the building, and a third region which provides part of the floor structure of the building.