Sandwich Panel Building Module with Integrated Metal Joists
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Solution Overview
Problem
The construction industry in New Zealand faces challenges in providing affordable housing due to limitations in the design of prefabricated dwellings, which are restricted by transportation constraints such as width, height, and length, leading to labor-intensive assembly and increased costs.
Innovation Solution
The development of a building module using a sandwich panel comprising an inner foamed core and an outer thermoplastic skin, with metal joists integrated within the panel, allowing for the creation of roof, wall, and floor structures that can be easily assembled and transported, while overcoming traditional design limitations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If prefabricated dwellings are constructed using conventional timber-framed components, then the design can be approved with multi-proof building consent, but the assembly becomes labor-intensive and complex
Solution Approach 1:
The patent combines multiple conventional components (timber framing, cladding, insulation, roofing, flooring) into a single integrated sandwich panel structure. The skin acts as both structural element and cladding, while the core provides insulation and rigidity, eliminating the need for separate assembly of multiple components and reducing labor intensity.
Solution Approach 2:
The invention uses composite sandwich panel construction with an outer skin and inner core made of different materials (e.g., thermoplastic and foamed material). This composite structure provides integrated structural strength, insulation, and weatherproofing in a single unit, reducing assembly complexity while maintaining building consent approval.
2Productivity
If prefabricated dwellings are transported as complete structures, then construction time is reduced, but transportation constraints limit design flexibility
Solution Approach 1:
The dwelling is divided into modular sandwich panels that can be transported efficiently within vehicle constraints. These panels are then assembled on-site to create various building configurations, maintaining both construction speed and design flexibility through modular assembly.
Solution Approach 2:
The sandwich panels are designed with optimized dimensions that fit within transportation constraints while providing sufficient structural area. The panels can be arranged in different configurations (single-story, multi-story, various floor plans) by changing their spatial arrangement rather than their individual dimensions.
3Strength
If sandwich panels are made with integrated metal joists and thermoplastic skin, then structural strength and weather-tightness are improved, but manufacturing complexity increases
Solution Approach 1:
The metal joists are integrated directly into the thermoplastic skin during the molding process, creating a single monolithic component. This merging of structural and cladding elements provides enhanced strength and weather-tightness while actually simplifying manufacturing by eliminating separate assembly steps.
Solution Approach 2:
The combination of thermoplastic skin and metal joists creates a composite structure where each material contributes its superior properties. The thermoplastic provides weather-tightness and corrosion resistance, while the metal joists provide structural strength, achieving both goals without significantly complicating manufacturing.
4Length of moving object
If building modules are designed to fit transportation constraints, then transportability is improved, but design freedom is reduced
Solution Approach 1:
The building is segmented into standardized sandwich panel modules with dimensions optimized for transportation. These modules can be combined in various numbers and configurations to create buildings of different sizes and layouts, maintaining design freedom while ensuring transportability.
Solution Approach 2:
The sandwich panels are designed as universal building blocks that can serve multiple functions (walls, roofs, floors, partitions) depending on their orientation and arrangement. This multi-functionality allows diverse building designs to be created from the same standardized modules, preserving design freedom within transportation constraints.
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 enables the efficient construction of buildings by allowing for the easy assembly and transportation of modular components, reducing labor costs and increasing design flexibility, while also providing a durable and weather-tight structure.
Implementation Method 1
forming the skin of the sandwich panel in said mould, by adding a thermoplastic material, and rotating the mould in a rotary oven
Implementation Method 2
allowing the thermoplastic to set and cure
Implementation Method 3
an inner core comprising a foamed material
Data Source
AI summary
Methods for constructing 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 building, and a third region which provides part of the floor structure of the building.