Sealed Insulated Panel Mold with Anchor Extensions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Insulated concrete panels face structural integrity issues due to moisture penetration, which can lead to mold growth and rot, and existing solutions like shotcrete or cement plaster coatings are costly and prone to cracking or degradation.
Innovation Solution
A method of forming insulated panels using a mold bulkhead with a sealing strip that includes anchor extensions and a panel cap, where the sealing strip defines a sealed insulation zone, and curable building material is introduced to form slabs that surround the anchor extensions, creating a durable moisture barrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If shotcrete or cement plaster coating is applied to insulated panels, then moisture protection is improved, but manufacturing complexity and production time increase
Solution Approach 1:
The sealing strip is attached to the mold bulkhead before pouring the concrete slabs, creating the moisture barrier as part of the initial manufacturing process rather than as a subsequent coating step. This preliminary action integrates moisture protection into the panel fabrication itself, eliminating the need for separate shotcrete or plaster coating operations.
Solution Approach 2:
The invention combines the moisture sealing function with the structural concrete slab formation by integrating the sealing strip into the mold bulkhead assembly. The sealing strip, anchor extensions, and concrete slabs work as a unified system where the seal is created during the same manufacturing cycle as the structural elements, merging protective and structural functions.
2Reliability
If shotcrete or cement plaster coating is applied to insulated panels, then moisture protection is improved, but production time increases
Solution Approach 1:
The sealing strip is installed on the mold bulkhead before the concrete pouring operation begins, allowing the moisture barrier to be established as part of the initial formwork preparation. This preliminary placement eliminates the need for separate coating applications and curing time that would be required for shotcrete or plaster layers.
Solution Approach 2:
The sealing strip system is designed to be self-integrating with the concrete slabs through the anchor extensions that become embedded in the curing concrete. The system creates its own moisture barrier without requiring additional manual coating operations or external application processes, thereby reducing production time.
3Reliability
If coating material is applied to insulated panels, then moisture protection is improved, but the coating may crack, flake, chip, and degrade
Solution Approach 1:
The sealing strip is integrated with the concrete slabs through anchor extensions that become embedded in the curing concrete, creating a unified structural-sealing system. This integration ensures that the moisture barrier moves and deforms with the concrete structure itself, eliminating the separation and interface failures that cause cracking, flaking, and chipping in applied coatings.
Solution Approach 2:
The system combines the sealing strip material with the concrete slab through mechanical interlocking via anchor extensions. This composite construction creates a durable assembly where the sealing function and structural function are combined, preventing the degradation issues associated with separate applied coatings that are not mechanically bonded to the substrate.
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 method effectively seals the insulation zone, preventing moisture ingress and maintaining structural integrity while avoiding additional manufacturing steps and material degradation, thus enhancing the durability and energy efficiency of insulated panels.
Implementation Method 1
introducing a curable building material into the interior mold volume to form a first slab... allowing the curable building material to cure to provide a cured insulated panel
Data Source
AI summary
Insulated panels and methods of forming insulated panels are provided. According to the method, mold bulkhead and a sealing strip including a first anchor extension, a second anchor extension, and a panel cap are provided. The method also includes removably attaching the exterior face of the sealing strip to the interior mold surface on at least one of the plurality of mold sides, wherein the first anchor extension and the second anchor extension project into the interior mold volume, and wherein the sealing strip defines a sealed insulation zone. A curable building material is introduced into the interior mold volume to form a first slab. The first slab at least partially surrounds the first anchor extension. The method also includes inserting an insulation material layer into the interior mold volume, wherein the insulation material layer is at least partially within the sealed insulation zone. A curable building material is introduced into the interior mold volume adjacent to the insulation material layer to form a second slab. The second slab at least partially surrounds the second anchor extension. The method also includes the step of allowing the curable building material to cure to provide a cured insulated panel, wherein the panel cap defines at least a portion of at least one of the plurality of intermediate faces.