3D Wire Mesh Concrete Wall Panel for Lightweight Insulated Construction
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Solution Overview
Problem
Existing construction panels are heavy, requiring significant labor and equipment for transportation and placement, and lack sound dampening, thermal insulation, and fire retardation capabilities.
Innovation Solution
A 3D wire mesh panel enveloped with structural material, such as concrete, incorporating a foam form for additional insulation and sound dampening, allowing on-site production and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional construction panels are used, then structural strength is maintained, but weight increases significantly requiring heavy equipment and labor for transportation and placement
Solution Approach 1:
The patent employs a composite structure combining a lightweight foam core (polystyrene or similar material) with a reinforcing wire mesh framework and concrete coating. This composite construction achieves the desired structural strength while dramatically reducing the overall panel weight compared to traditional solid concrete panels, enabling easier transportation and placement with standard equipment.
Solution Approach 2:
The foam core provides a porous, lightweight structure that reduces panel weight while the wire mesh reinforcement and concrete coating ensure structural integrity. The porous foam material maintains strength-to-weight ratio advantages while allowing for thermal insulation and sound dampening properties.
2Object-affected harmful factors
If traditional concrete panels are used, then fire retardation is provided, but sound dampening and thermal insulation capabilities are insufficient
Solution Approach 1:
The composite construction combines foam core material known for thermal insulation properties with concrete coating for fire retardation. The foam core provides sound dampening capabilities while the concrete outer layer maintains fire resistance, achieving multiple performance requirements simultaneously without significantly increasing weight.
Solution Approach 2:
Different materials are applied to different functional requirements: the foam core provides thermal insulation and sound dampening, while the concrete coating provides fire retardation and structural strength. Each layer performs its specific function optimally without requiring the entire panel to be made of heavy material.
3Ease of operation
If heavy panels are used to ensure structural integrity, then strength requirements are met, but transportation and placement require significant equipment and labor
Solution Approach 1:
The lightweight foam core combined with wire mesh reinforcement and concrete coating provides sufficient structural integrity for building applications while reducing the overall weight to a level that can be handled and positioned with standard construction equipment and minimal labor, significantly improving ease of operation.
Solution Approach 2:
The panel is constructed as a segmented composite structure with distinct functional layers (foam core, wire mesh, concrete coating) that can be manufactured separately and assembled, allowing for optimized weight distribution and structural strength while maintaining ease of transportation and placement.
4Ease of manufacture
If panels are designed for on-site production, then transportation costs and equipment requirements are reduced, but manufacturing complexity increases
Solution Approach 1:
The panel is designed as a segmented composite structure that can be manufactured in modular sections and assembled on-site. The foam core, wire mesh reinforcement, and concrete coating can be applied in sequential steps using standard construction materials and tools, reducing the need for complex specialized equipment while enabling on-site production.
Solution Approach 2:
The manufacturing process utilizes parameter changes in the concrete (from liquid to cured state) to achieve panel formation. By controlling concrete pouring, vibration, and curing parameters, the panel can be produced on-site with standard equipment, transforming a potentially complex manufacturing process into a manageable construction activity.
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 solution results in a lightweight panel that provides sound dampening and thermal insulation, reducing transportation and labor costs while meeting building requirements, with the ability to be precast on-site or off-site.
Implementation Method 1
incorporating a foam form for additional insulation and sound dampening
Implementation Method 2
incorporating a foam form for additional insulation and sound dampening
Implementation Method 3
allowing the panel to settle into the uncured concrete so there is uncured concrete below and around all sides of the panel and the uncured concrete bonds with the panel
Implementation Method 4
There is the step of letting the uncured concrete about the panel cure
Data Source
AI summary
A wall having a 3D wire mesh panel having a core with a 3D wire mesh matrix extending through and out the core, and a structural material, such as concrete, envelopes the panel. A form positioned about the panel is used to introduce the concrete to the panel during production. Methods for producing the wall, which include producing the wall vertically at a desired location.