Wall assembly with improved thermal insulation properties

Abstract

A wall includes a thermal chamber assembly having a radiant panel layer, a heat generation system connected to the radiant panel layer, a first insulation layer connected to the radiant panel layer opposite the heat generation system, and a radiation barrier layer connected to the first insulation layer between the first insulation layer and the radiant panel layer. The wall also includes a ventilation cavity assembly connected to the thermal chamber assembly, the ventilation cavity assembly having a second insulation layer connected to the first insulation layer opposite the radiation barrier layer, a gas barrier layer connected to the second insulation layer opposite the radiation barrier layer to establish a first gas layer between the second insulation layer and the gas barrier layer, and an outer layer connected to the gas barrier layer opposite the second insulation layer to establish a second gas layer between the gas barrier layer and the outer layer.

Description

Background Technology

[0001] Rising energy costs have driven expectations for buildings with increased energy efficiency. Improved energy efficiency is particularly desirable in extreme climates, such as hot deserts or regions often subjected to Arctic temperatures. While progress has been made in energy-efficient buildings, further advancements in energy efficiency are still being sought. Additionally, improvements are being made in cost efficiency and construction time efficiency. Summary of the Invention

[0002] One or more embodiments provide a wall. The wall includes a thermal chamber assembly. The thermal chamber assembly includes a radiant plate layer having a first range of thermal conductivity. The thermal chamber assembly also includes a heat generation system connected to the radiant plate layer. The thermal chamber assembly further includes a first insulating layer connected to the radiant plate layer opposite to the heat generation system and having a second range of thermal conductivity lower than the first range. The thermal chamber assembly also includes a radiation blocking layer connected between the first insulating layer and the radiant plate layer, the radiation blocking layer having the first range of thermal conductivity. The wall also includes a ventilation cavity assembly connected to the thermal chamber assembly. The ventilation cavity assembly includes a second insulating layer connected to the first insulating layer opposite to the radiation blocking layer, the second insulating layer having the second range of thermal conductivity. The ventilation cavity assembly also includes a gas blocking layer connected to the second insulating layer opposite to the radiation blocking layer. The gas barrier layer is connected to the second insulating layer at a first distance to establish a first gas layer between the second insulating layer and the gas barrier layer. The ventilation cavity assembly also includes an outer layer, which is connected to the gas barrier layer opposite to the second insulating layer. The outer layer is connected to the gas barrier layer at a second distance to establish a second gas layer between the gas barrier layer and the outer layer.

[0003] One or more embodiments provide a method of manufacturing. The method includes manufacturing wall segments. Each wall segment includes a thermal chamber assembly. The thermal chamber assembly includes a radiant plate layer having a first range of thermal conductivity. The thermal chamber assembly also includes a heat generation system connected to the radiant plate layer. The thermal chamber assembly further includes a first insulating layer connected to the radiant plate layer opposite to the heat generation system. The first insulating layer has a second range of thermal conductivity lower than the first range. The first insulating layer also includes a first end and a second end opposite the first end in length relative to the first insulating layer. The first insulating layer also includes a tenon extending from the first end. The first insulating layer also includes a groove extending into the second end. The thermal chamber assembly further includes a radiation blocking layer connected between the first insulating layer and the radiant plate layer, the radiation blocking layer having the first range of thermal conductivity. The wall also includes a ventilation cavity assembly connected to the thermal chamber assembly. The ventilation cavity assembly includes a second insulating layer connected to the first insulating layer opposite to the radiation blocking layer, the second insulating layer having a thermal conductivity of the second range. The ventilation cavity assembly also includes a gas blocking layer connected to the second insulating layer opposite to the first insulating layer. The gas blocking layer is connected to the second insulating layer at a first distance to establish a first gas layer between the second insulating layer and the gas blocking layer. The ventilation cavity assembly also includes an outer layer connected to the gas blocking layer opposite to the second insulating layer. The outer layer is connected to the gas blocking layer at a second distance to establish a second gas layer between the gas blocking layer and the outer layer. The method further includes transporting the wall segment to a construction site. The method also includes connecting the wall segment by connecting the tenon of the first wall segment in the wall segment to the groove of the second wall segment in the wall segment.

[0004] One or more embodiments also provide a thermal insulation method. The method includes constructing a building comprising a wall. The wall includes a thermal chamber assembly. The thermal chamber assembly includes a radiant plate layer having a first range of thermal conductivity. The thermal chamber assembly also includes a heat generation system connected to the radiant plate layer. The thermal chamber assembly further includes a first insulating layer connected to the radiant plate layer opposite to the heat generation system. The thermal chamber assembly has a second range of thermal conductivity lower than the first range. The thermal chamber assembly also includes a first end and a second end opposite the first end in length relative to the first insulating layer. The thermal chamber assembly also includes a tenon extending from the first end. The thermal chamber assembly also includes a groove extending into the second end. The thermal chamber assembly further includes a radiation blocking layer connected between the first insulating layer and the radiant plate layer, the radiation blocking layer having the first range of thermal conductivity. The wall also includes a ventilation cavity assembly connected to the thermal chamber assembly. The ventilation cavity assembly includes a second insulating layer connected to the first insulating layer opposite to the radiation blocking layer, the second insulating layer having a thermal conductivity of the second range. The ventilation cavity assembly also includes a gas blocking layer connected to the second insulating layer opposite to the first insulating layer. The gas blocking layer is connected to the second insulating layer at a first distance to establish a first gas layer between the second insulating layer and the gas blocking layer. The ventilation cavity assembly also includes an outer layer connected to the gas blocking layer opposite to the second insulating layer. The outer layer is connected to the gas blocking layer at a second distance to establish a second gas layer between the gas blocking layer and the outer layer. The method further includes generating heat or cooling using the heat generation system and directing the heat or cooling to the radiation plate layer.

[0005] Other aspects of one or more embodiments will become apparent from the following description and the appended claims. Attached Figure Description

[0006] Figure 1 A wall assembly according to one or more embodiments is shown.

[0007] Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 and Figure 7 An illustration is provided according to one or more embodiments. Figure 1 Details of the wall assembly shown.

[0008] Figure 8 A manufacturing method according to one or more embodiments is shown.

[0009] Figure 9 A thermal insulation method according to one or more embodiments is shown.

[0010] For consistency, the same elements in the various figures are represented by the same reference numerals. Detailed Implementation

[0011] One or more embodiments relate to a wall assembly with improved thermal insulation properties. Compared to existing wall assemblies, the wall assembly provides quantitatively improved thermal insulation properties. Additionally, the wall assembly of one or more embodiments can be manufactured at a manufacturing facility and then transported to a construction site for rapid assembly. Therefore, the wall assembly of one or more embodiments also provides increased cost efficiency and construction time efficiency.

[0012] One or more embodiments of the wall assembly include a first set of layers forming a heat-generating chamber and a second set of layers forming a ventilation chamber. Together, these two sets of layers not only serve as a thermal barrier between the internal and external portions of the wall assembly to mitigate extreme temperature differences, but also provide active heating or cooling for the interior of a building constructed using the wall assembly of one or more embodiments.

[0013] The heat generation chamber includes a radiating plate layer having a first range of thermal conductivity. In some embodiments, the first range of thermal conductivity can be within the range considered to be high thermal conductivity, such as thermal conductors (e.g., metals) as defined by engineers. While high thermal conductivity materials can transfer heat efficiently when in direct contact with other materials, they also tend to reflect radiant energy (e.g., infrared light) and can therefore be formed as part of a wall assembly exhibiting improved thermal insulation properties.

[0014] The heat generation chamber also includes a heat generation system located within the radiant panel layer relative to the interior of the building, which is partially formed by walls. The heat generation system may be a system of heated or cooled liquid piping, or it may be some other heater or air conditioning system.

[0015] The interior finishing layer (e.g., drywall, plaster, etc.) can be located inside the heat generation system relative to the interior of the building. The interior finishing layer can face the interior of the building (i.e., form the interior wall as seen by people inside the building).

[0016] The heat generation chamber also includes a first insulating layer, which is connected to the radiant panel layer relative to the heat generation system (i.e., relative to the interior of the building, outside the radiant panel layer). The first insulating layer has a second range of thermal conductivity lower than a first range of thermal conductivity of the radiant panel layer. The second range of thermal conductivity can be considered as an insulator and therefore has a low thermal conductivity as defined by the engineer.

[0017] The heat generation chamber also includes a radiation blocking layer connected between the radiation plate layer and the first insulating layer. The radiation blocking layer can also be a thermal conductor and therefore can have the same first range of thermal conductivity as the radiation plate layer.

[0018] The wall assembly also includes a ventilation cavity assembly. The ventilation cavity assembly creates a dead air layer (i.e., air that does not move or moves less than the air inside or outside the wall assembly). Dead air, or some other gases, has low thermal conductivity.

[0019] The ventilation cavity assembly includes a second insulation layer connected to a first insulation layer of the heat-generating chamber. Therefore, the second insulation layer is located outside the first insulation layer relative to the interior of the building. The second insulation layer may have a low thermal conductivity and is therefore within a second range of thermal conductivity of the first insulation layer. A pipe disposed within the second insulation layer can create a separation between the first and second insulation layers, thereby creating a space (filled with gas, such as air) between the two insulation layers.

[0020] The ventilation cavity assembly also includes a gas barrier layer connected to the second insulation layer opposite to the first insulation layer. Therefore, the gas barrier layer is located outside the second insulation layer relative to the interior of the building. The gas barrier layer is connected to the second insulation layer at a first distance to establish a first gas layer between the second insulation layer and the gas barrier layer.

[0021] The ventilation cavity assembly also includes an outer layer connected to the gas barrier layer opposite to the second insulating layer. Therefore, the outer layer is located outside the gas barrier layer relative to the interior of the building. The outer layer may face the exterior of the building (i.e., the outer layer may face external components). The outer layer may be connected to the gas barrier layer at a second distance to establish a second gas layer between the gas barrier layer and the outer layer.

[0022] Additional layers and components can be added to the aforementioned wall assembly. For example, thermal insulation materials (such as cork) or other materials can be placed between the layers to serve as additional thermal insulation between them. Electrical systems or Ethernet systems can be added between the wall layers, possibly with exposed outlets, such as in the inner finish layer or the outer layer.

[0023] The wall assembly described above can also incorporate modular features. For example, tenon and groove features can be added to one or more of the aforementioned layers. Tenon and groove features allow for rapid alignment of wall sections on the construction site. Thus, wall sections can be efficiently manufactured at the manufacturing facility and then transported to the construction site for rapid assembly.

[0024] Furthermore, manufacturing wall assemblies at a manufacturing facility can reduce the carbon footprint of manufacturing and assembling walls. For example, carbon emissions during the manufacturing process can be controlled at the manufacturing facility. Additionally, heavy construction equipment at construction sites may burn fuel during construction. Because buildings using wall assemblies from one or more embodiments are time-efficient, such equipment operates for less time, thus further reducing the building's carbon footprint.

[0025] The aforementioned wall assembly can be referred to as the "Miralex Wall System." The Miralex Wall System is suitable for both new construction and building renovations. It can be used to construct many types of buildings, including houses, multi-unit apartments, condominiums, hospitals, schools, daycare centers, community centers, and commercial buildings.

[0026] The Miralex wall system is also very robust. It can withstand winds of up to approximately 9,250 Pascals and can be exposed to all types of weather (sun, snow, ice, water, strong winds, etc.). The Miralex wall system has excellent energy performance, with an insulation rating exceeding at least R20 even under extreme weather conditions (e.g., hot deserts or Arctic climates).

[0027] The radiant lining (i.e., the aforementioned radiant panels and radiant blocking layers) allows heat and cold sources to be transferred to the interior of the building envelope through heat generation. In this way, humidity can be controlled without affecting the moisture content of the envelope and materials. Therefore, the external ventilation assemblies can be kept dry.

[0028] The Miralex wall system also reduces thermal bridging in wall assemblies, a feature observed in other wall designs within conventional building assemblies. Therefore, the Miralex wall system improves heating and cooling performance, thereby continuously reducing energy consumption.

[0029] Solar panels can be located outside the outer layer (or elsewhere on the building formed at least partially by the Miralax wall system). Solar energy can be accumulated in the cells and used by the building occupants, or by a heat generation system in the thermal chamber assembly.

[0030] Now let’s turn our attention to the attached figures. Figure 1A wall assembly according to one or more embodiments is shown. The wall assembly (100) includes a heat generation chamber assembly (102) and a ventilation chamber assembly (104). Each of the assemblies is described sequentially.

[0031] The heat generation chamber assembly (102) includes a radiating plate (106). The radiating plate (106) is a high thermal conductivity material within a first range of thermal conductivity. The term "high thermal conductivity" is assessed by a building engineer and can be considered as a thermal conductor that also reflects infrared light. Examples of materials that can form the radiating plate (106) include aluminum, steel, iron, titanium, etc., but other materials that reflect infrared light can be used.

[0032] In one embodiment, such as Figure 1 In the embodiment shown, the radiant panel (106) may be corrugated aluminum. The corrugations in the corrugated aluminum forming the radiant panel (106) may create a partition between the radiant panel (106) and the inner finishing layer (120) (described below), or between the radiant panel (106) and the first insulating layer (110), or both. The partition may create a space within the heat-generating chamber assembly (102). The space allows for the circulation of heated or cooled gases and also provides additional insulation relative to the exterior of the wall assembly (100).

[0033] The heat-generating chamber assembly (102) of the wall assembly (100) also includes a heat-generating system (108). The heat-generating system (108) is connected to the radiant panel layer (106) or the interior finish layer (120) (described below). The heat-generating system (108) is a heating system, a cooling system, or both, depending on the type of heat-generating system (108) required for the climate in which the wall assembly (100) will be used to construct the building.

[0034] For example, the heat generation system (108) can be designed to heat the heat generation chamber assembly (102) in cold climates. As an example, the heat generation system (108) can be an interconnected series of pipes for conveying hot water. Hot water can be pumped through the pipes, thereby providing heat. The water can be heated in a furnace located outside the wall assembly (100) and then pumped into and connected to the pipes through an inlet into the wall, or it can be heated by electrical components contained within the wall assembly (100). As another example, the heat generation system (108) can be an electric heating system that uses electricity to heat components connected to the radiant panel layer (106) or the heat generation system (108). As yet another example, the heat generation system (108) can be a pipe designed to blow heated gas through the pipes. The gas can be heated by a furnace outside the wall assembly (100) and then pumped into the wall through an inlet and connected to the pipes. Heated gas can also be pumped into a pipe and then blown into the gap space within the heat generation chamber assembly (102) (e.g., between the radiant plate layer (106) and the heat generation system (108), between the first insulation layer (110) and the second insulation layer (114), between the radiant plate layer (106) and the inner veneer layer (120) (described below) or a combination thereof).

[0035] However, the heat generation system (108) can be designed to cool the heat generation chamber assembly (102) in hot climates. For example, as described above, the heat generation system (108) can be a liquid cooling system or a gas cooling system via a pipe that pumps cooling liquid or cooling gas. As another example, the heat generation system (108) can also be an air conditioning system, or can be attached to an air conditioning system. Thus, for example, the heat generation system (108) can be a pipe connected to an air conditioning compressor located outside the wall assembly (100) via one or more inlets in the wall and connected to a pipe. The pipe can blow cool air into the space defined within the heat generation chamber assembly (102) (e.g., between the radiant panel layer (106) and the heat generation system (108), between the first insulation layer (110) and the second insulation layer (114), between the radiant panel layer (106) and the interior finish layer (120) (described below) or combinations thereof).

[0036] The heat generation chamber assembly (102) also includes a radiation blocking layer (112). The radiation blocking layer (112) may be connected between the first insulating layer (110) and the radiating plate layer (106) (described below). Similar to the radiating plate layer (106), the radiation blocking layer (112) may be within a first range of thermal conductivity. Therefore, the radiation blocking layer (112) may be a layer of aluminum, steel, or other materials similar to those described above for the radiating plate layer (106).

[0037] As described above, the heat generation chamber assembly (102) also includes a first insulating layer (110). The first insulating layer (110) is a material having a second range of thermal conductivity lower than the first range of thermal conductivity described above for the radiating plate layer (106). The second range of thermal conductivity may be less than the first range of thermal conductivity of the radiating plate layer (106). The first insulating layer (110) may be formed of a material considered to be a thermal insulator. Examples of materials that can form the first insulating layer (110) include glass fiber, cellulose, polystyrene, aerogel, vacuum insulation board, mica, plastic, rubber, glass wool, certain composite materials, etc. Therefore, the first insulating layer (110) serves to insulate against heat transfer (possibly together with the gas-filled empty space defined between the first insulating layer (110) and the second insulating layer (114), as indicated by arrow (111).

[0038] Along the axis (126) relative to the length of the radiating plate layer (106), the first insulating layer (110) includes a first end (122) and a second end (124) opposite to the first end (122). A tenon (128) extends outward from the first end (122) relative to the axis (126). A groove (130) extends inward into the second end (124) relative to the axis (126). In use, the tenon (128) of one wall segment of the wall assembly (100) can be fitted into the groove (130) of another wall segment of the wall assembly (100), thereby facilitating the alignment and assembly of the two wall segments together.

[0039] Additionally, when joined, the tongue (128) and groove (130) can form a moisture barrier at each vertical end of the wall panel. The tongue (128) and groove (130) can establish the continuity of the internal system's moisture barrier, air barrier assembly, and thermal bridge connection from the thermal insulation to the floor and ceiling level of the wall assembly.

[0040] The tenon (128) may be an extension of the insulating material forming the first insulating layer (110). However, the tenon (128) may be a different material object attached to the first end (122) of the first insulating layer (110).

[0041] In one embodiment, the interior finishing layer (120) may be connected to the radiant panel layer (106) opposite to the radiation blocking layer (112). Therefore, the interior finishing layer (120) may be located inside the radiant panel layer (106) relative to the interior of the building. The interior finishing layer (120) may face the interior of the building. The aforementioned heat generation system (108) may be disposed between the radiant panel layer (106) and the interior finishing layer (120).

[0042] In one embodiment, a cork strip (132) may be disposed around the periphery of the first insulating layer (110) between the first insulating layer and the second insulating layer (114) (described below). Insulating materials other than cork may be used instead of the cork strip (132). Therefore, one or more embodiments are not limited to the use of cork. The cork strip (132) (or other insulating strip) may establish a thermal barrier between the metal assembly (e.g., the tube described below) and other components of the wall assembly (100).

[0043] Now turn attention to the ventilation chamber assembly (104) of the wall assembly (100). The ventilation chamber assembly (104) includes a second insulating layer (114). The second insulating layer (114) is connected to the first insulating layer (110) opposite to the radiation blocking layer (112). The second insulating layer (114) may be a material having a second range of thermal conductivity, as described above with respect to the first insulating layer (110). In one embodiment, the second insulating layer (114) may be thicker than the first insulating layer (110) along the axis (148).

[0044] The head frame (136) can extend from the second insulating layer (114). Specifically, the head frame (136) can extend upward from the top of the second insulating layer (114) relative to the direction of gravity. In one embodiment, the direction of gravity is indicated by an arrow on the vertical axis (138).

[0045] One or more tubes may be disposed within or partially disposed within the second insulating layer (114). The tubes may be formed of a material with a thermal conductivity within a first range (e.g., a metal), or may be formed of other materials with a thermal conductivity within a second range (e.g., composite materials) (e.g., insulators such as wood, composite materials, plastics, etc.). However, in one embodiment, the tubes may form structural members that both support the wall against compressive forces exerted in the direction of gravity (i.e., along the vertical axis (138)) and facilitate the containment of the insulating material forming the second insulating layer (114).

[0046] For example, a first tube (140) is connected to a second insulating layer (114). The first tube (140) is disposed in the second insulating layer (114) and extends inward along the axis (148) toward the first insulating layer (110). (See example) Figure 4 The first tube (140) is also positioned along the height of the second insulating layer (114) relative to the direction of gravity as shown by the vertical axis (138).

[0047] Similarly, a second tube (142) is connected to a second insulating layer (114). The second tube (142) is disposed in the second insulating layer (114) and extends outward along the axis (148) toward the gas barrier layer (116). (See example) Figure 4 The second tube (142) is also positioned along the height of the second insulating layer (114) relative to the direction of gravity as shown by the vertical axis (138).

[0048] In one embodiment, a similar tube is also positioned relative to the axis (126) at the opposite end of the second insulating layer (114). Thus, for example, a third tube (143) connected to the second insulating layer (114) is... Figure 1 The first tube (140) is shown opposite the second tube (142). Similarly, a fourth tube (not shown) connected to the second insulating layer (114) can be positioned opposite the first tube (140).

[0049] The bottom frame (144) may be positioned around the second insulation layer (114). The bottom frame (144) is positioned at the bottom of the second insulation layer (114) relative to the direction of gravity as shown by the vertical axis (138). The bottom frame (144) may surround the second insulation layer (114) or the tube, thereby serving as a support to help hold the tube and the insulating material forming the second insulation layer (114).

[0050] Similarly, the top frame (145) may be positioned around the second insulation layer (114). The bottom frame (144) is positioned at the top of the second insulation layer (114) relative to the direction of gravity indicated by the vertical axis (138). The top frame (144) may surround the second insulation layer (114) or the tube, thereby serving as a support to help hold the tube and the insulating material forming the second insulation layer (114). The aforementioned head frame (136) may be part of the top frame (145). However, the top frame (145) may also be a separate component to which the head frame (136) is attached, or the head frame (136) may extend from the separate component.

[0051] An additional cork strip (134) may be disposed around the periphery of the second insulation layer (114) on the side of the second insulation layer (114) facing the gas barrier layer (116) (described below). The additional cork strip (134) may serve as additional thermal insulation. Insulating materials other than cork may be used instead of the additional cork strip (134). Therefore, one or more embodiments are not limited to the use of cork.

[0052] The ventilation chamber assembly (104) also includes a gas barrier layer (116). The gas barrier layer (116) is connected to a second insulating layer (114) opposite to the first insulating layer (110). In one embodiment, the gas barrier layer (116) is directly connected to the second insulating layer (114), or it can be indirectly connected to the second insulating layer (114) via a cork strip (see example). Figure 5 and Figure 6 ).

[0053] In another embodiment, the gas barrier layer (116) is connected to the second insulating layer (114) at a first distance to establish a first gas layer between the second insulating layer (114) and the gas barrier layer (116). For example, a gasket (146) may be connected to the second insulating layer (114) and the gas barrier layer (116). In one embodiment, the width of the gasket (146) along the axis (148) matches or exceeds the said distance.

[0054] Alternatively, or in addition to the gasket (146), other means may be present to establish a separation between the second insulating layer (114) and the gas barrier layer (116). For example, a tube (e.g., a second tube (142)) may extend outward from the second insulating layer (114). In this case, the gas barrier layer (116) may be connected to the tube. Furthermore, a bottom frame (144) may also extend outward from the second insulating layer (114) or from the tube, also establishing a separation between the second insulating layer (114) and the gas barrier layer (116). In this case, the bottom frame (144) may be connected to both the gas barrier layer (116) and the second insulating layer (114).

[0055] The second insulating layer (114) serves to insulate against heat transfer (possibly together with the gas layer defined between the second insulating layer (114) and the gas barrier layer (116), as indicated by arrow (113). Thus, a multilayer of insulating material, gas, and heat-reflective material is established between the exterior and interior of the wall assembly (100).

[0056] The ventilation chamber assembly (104) also includes an outer layer (118). The outer layer (118) (at least indirectly via the outer frame (152) (described below)) is connected to a gas barrier layer (116) opposite the second insulation layer (114). The outer layer (118) is connected to the gas barrier layer (116) at a second distance along an axis (148) to establish a second gas layer between the gas barrier layer (116) and the outer layer (118).

[0057] In one embodiment, a plurality of clips (such as clip (150)) establish a second distance between the gas barrier layer (116) and the outer frame (152) along an axis (148). However, other objects (e.g., gaskets (similar to gasket (146))) can be used to establish the second distance and thus form a second gas chamber. Similarly, tubes (similar to the first tube (140) and the second tube (142) described above) or other objects can therefore be used to establish a distance to form a second gas chamber. The clips can be formed of an insulating material (e.g., plastic or carbon composite), but in other embodiments, the clips can be formed of a thermal conductor (e.g., metal).

[0058] In another instance, such as Figure 1 As shown, because the outer frame (152) is connected to the clip, and because the outer layer (118) is connected to the outer frame (152), the clip and the outer frame (152) together can establish a second distance. In yet another embodiment, the outer frame (152) itself can establish a second distance.

[0059] The outer frame (152) can be a structural member that helps to bear the load borne by the wall assembly (100). Therefore, the outer frame (152) can be made of metal, but can also be made of a strong insulating material such as carbon composite material.

[0060] In one embodiment, a first set of insulating blocks is disposed between at least some of the clips, the gas barrier layer (116), and the outer layer (118). Additionally, a second set of insulating blocks may be disposed between the second insulating layer (114) and the gas barrier layer (116). The insulating blocks can provide additional thermal insulation against heat transfer between the various layers of the ventilation chamber assembly (104).

[0061] Finally, the ventilation chamber assembly (104) includes an outer layer (118). The outer layer (118) is at least indirectly connected to the gas barrier layer (116) (e.g., the outer layer (118) is connected to an outer frame (152), which in turn is connected to the gas barrier layer (116) via clips (such as clips (150)). In the illustrated embodiment, the outer layer (118) is directly connected to the outer frame (152).

[0062] The outer layer (118) may be an exterior wall panel suitable for exposure to outdoor elements (e.g., metal, wood, stone, ceramic, composite materials, etc.). In one embodiment, the outer layer (118) may be corrugated, such as... Figure 1 As shown in the figure, but in other embodiments, the outer layer (118) may be a flat sheet of material or a series of plates. In some embodiments, the outer layer (118) may be a rain shield.

[0063] In one embodiment, the waterproofing membrane (158) may be positioned along a vertical edge of the outer layer (118), as defined by a vertical axis (138). When a wall assembly (100) is joined to another wall segment, the waterproofing membrane (158) may extend over any joint that may exist between the multiple wall segments. For example, when one wall assembly (100) segment is joined to another wall assembly (100) segment, the waterproofing membrane (158) may extend over and cover the joint between the outer layers (118) of the two wall assembly segments.

[0064] The wall assembly (100) may be provided with additional features. For example, a power outlet (160) may be connected to or housed within the interior finish layer (120). Electrical wiring placed in the space between the interior finish layer (120) and the radiant panel layer (106) may be connected to a power source (not shown, but for example, to a power transmission cable). Thus, electrical devices may be connected to the power outlet (160) and thereby connected to a power source.

[0065] In one embodiment, an additional power outlet may be connected to or disposed within the outer layer (118). Similar electrical wiring in the space defined between the gas barrier layer (116) and the outer layer (118) may connect the power outlet to a power source. Thus, electrical devices may be connected to the power outlet within the outer layer (118) and power electrical devices outside the wall assembly (100).

[0066] In one embodiment, a heat generation system outlet (162) may be connected to or disposed within the interior finish layer (120). The heat generation system outlet (162) may be an inlet, manifold, etc., for connecting an external liquid source (e.g., a hot water tank) to the heat generation system (108). The heat generation system outlet (162) may also be a vent for connecting an external source of heated or cooled air (e.g., a furnace or air conditioning compressor) to the heat generation system (108). The heat generation system outlet (162) may also be a passive vent that allows air to circulate in and out of the interior of a building partially formed by the wall assembly (100) and the space defined between the interior finish layer (120) and the radiant panel layer (106).

[0067] The wall assembly (100) may be provided with other goods. For example, interior finishes including electrical outlets and other goods may be provided. In another example, the outer layer (118) may be high-performance glass, shading and daylighting components (e.g., windows may be housed within the wall assembly (100)). Windows may be housed through these layers to allow light to pass from the exterior of the building, at least partially formed by the wall assembly (100), into the interior. Windows may be constructed of multiple layers of material to increase the thermal insulation properties of the windows. Other variations are also possible.

[0068] For example, solar panels can be connected to a wall assembly (100), or may include electrical wiring that can be connected to a power source, such as solar panels. When the power source is solar panels, the heat generation system (108) can be powered by a grid of solar panels mounted via ground mounts, pole mounts, roof mounts, wall mounts, etc. Solar panels can be placed in the arched shoulder of a glass window. Additional features (such as solar blinds and solar shades) can be provided, where the generated solar energy is distributed to a hybrid inverter, converted into usable electricity, and then stored in one or more batteries. When the external electrical grid is unavailable or low in power, one or more batteries can provide energy to power the heat generation system (108).

[0069] Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 , Figure 8 and Figure 9 An illustration is provided according to one or more embodiments. Figure 1 Details of the wall assembly shown. Therefore, Figures 2 to 9 It shows about Figure 1 Different views of the wall assembly (100) or its various parts as described. Therefore, Figures 1 to 9 Shared common reference numerals, which refer to the figures above concerning... Figure 1 The common object or component described.

[0070] Figure 2 It shows Figure 1 A side view of the wall assembly (100) shown. Specifically, Figure 2 The wall assembly (100) shown illustrates one side of the second end (124) of the wall assembly (100), which includes the second insulating layer (114).

[0071] The layers are shown as interconnected. These layers include an inner veneer layer (120), a radiant panel layer (106), a heat generation system (108), a first insulation layer (110), a radiation blocking layer (112), a second insulation layer (114), a gas blocking layer (116), and an outer layer (118). Other components are also visible, such as clips (150), an outer frame (152), a head frame (136), a first tube (140), a second tube (142), and a heat generation system socket (162).

[0072] The inner (200) and outer (202) sides of the wall assembly (100) are shown for reference. The inner (200) faces the interior of the building at least partially formed by the wall assembly (100). The outer (202) faces the exterior of the building at least partially formed by the wall assembly (100). However, if multiple wall segments are stacked in front of each other, the outer (202) of one wall may face the inner (200) of another wall. However, a floor may be referred to as the interior of another floor as long as it is closer to the interior of the building than another floor. Similarly, a floor may be referred to as the exterior of another floor as long as it is closer to the exterior of the building than another floor.

[0073] The wall assembly (100) is also marked with a section for reference. Figures 2 to 7 Therefore, for example, section AA (204) is shown ( Figure 3 ), Section C (206) ( Figure 5 ), Section D (208) Figure 6 ) and section E (210) Figure 7 For reference only. As an additional reference, Figure 3 Details of section B (300) in Figure 4 As shown in the image.

[0074] Now let's turn our attention to... Figure 3 . Figure 3 It shows Figure 3 Details of section AA (204) are shown. Section AA (204) shows the wall assembly (100) as viewed from above relative to the vertical axis (138). Similarly, various parts of the wall assembly (100) are shown for reference, including the inner veneer layer (120), the radiant panel layer (106), the heat generation system (108), the first insulation layer (110), the radiation blocking layer (112), the second insulation layer (114), the gas blocking layer (116), the outer layer (118), the first tube (140), the second tube (142), the clip (150), the outer frame (152), and the heat generation system socket (162). In addition, the heat generation chamber (302) (empty space) is in Figure 3 It is more clearly visible in the middle. The radiative transfer of heat energy is shown by arrows, such as arrow (304).

[0075] However, in Figure 1 In a variant of the embodiment shown, the ventilation cavity (306) is shown disposed between the gas barrier layer (116) and the outer layer (118), established by a partition between the outer layer (118) and the gas barrier layer (116). The latter partition may be established by an extension extending outward from the outer frame (152).

[0076] Figure 4As shown Figure 3 The section B (300) shown in the diagram illustrates the details of the wall assembly (100). The individual layers of the wall assembly (100) are shown in... Figure 4 The details of section B (300) shown are more readily visible. Thus, for example, the radiant plate layer (106), the heat generation system (108), the first insulation layer (110), the radiation blocking layer (112), the second insulation layer (114), the gas blocking layer (116), the outer layer (118), the inner finishing layer (120), and the outer frame (152) are shown for reference. A tenon (128) extending from the first insulation layer (110) and one of the clips (i.e., clip (400)) are also shown for reference. A third tube (143) and a fourth tube (402) are also shown for reference. The fourth tube (402) is relative to... Figure 1 The axis (126) shown is positioned opposite the first tube (140).

[0077] Figure 5 As shown Figure 2 Details of the wall assembly (100) shown in section C (206) are illustrated. Similarly, the inner veneer layer (120), radiant panel layer (106), heat generation system (108), first insulation layer (110), radiation blocking layer (112), second insulation layer (114), gas blocking layer (116), outer layer (118), first tube (140), second tube (142), bottom frame (144), clip (150), outer frame (152), waterproofing plate (158), and heat generation system socket (162) are shown for reference. Various examples of cork strips (132) demonstrate that cork strips (or other insulating strips) can be placed around or beneath various components to serve as thermal barriers between the aforementioned layers of the wall assembly (100).

[0078] Figure 6 It shows Figure 2 Details of section D (208) shown are illustrated. Similarly, the inner veneer layer (120), radiant panel layer (106), heat generation system (108), first insulation layer (110), radiation blocking layer (112), second insulation layer (114), gas blocking layer (116), outer layer (118), first tube (140), second tube (142), outer frame (152), and waterproofing membrane (158) are shown for reference. Various examples of cork strips (132) demonstrate that cork strips (or other insulating strips) can be placed around or beneath various components to serve as thermal barriers between the aforementioned layers of the wall assembly (100).

[0079] Figure 7 It shows Figure 2Details of section E (210) shown. The first insulating layer (110), radiation blocking layer (112), second insulating layer (114) and gas blocking layer (116) are shown for reference. Figure 7 An insulating frame (700) disposed externally around the second insulating layer (114) is also shown, which can be used to hold the second insulating layer (114) in place. Figure 7 In this example, the insulating frame (700) can be a metal strip or other structural material. Figure 1 The bottom frame (144) shown can be attached to the metal strip or other structural material.

[0080] Although Figures 1 to 7 The component configurations are shown, but other configurations can be used without departing from the scope of one or more embodiments. For example, various components can be combined to create a single component. As another example, the functionality performed by a single component can be performed by two or more components.

[0081] Figure 8 A manufacturing method according to one or more embodiments is shown. Figure 8 One method could be to manufacture a building using multiple wall assemblies, such as... Figures 1 to 7 The wall assembly (100) shown.

[0082] Step (800) includes manufacturing a plurality of wall segments. Each of the wall segments may be Figure 1 The wall assembly (100) shown.

[0083] Therefore, each of the wall segments may include a thermal chamber assembly. The thermal chamber assembly includes a radiating plate layer having a first range of thermal conductivity. The thermal chamber assembly also includes a heat generation system connected to the radiating plate layer.

[0084] The thermal chamber assembly also includes a first insulating layer connected to the radiating plate layer opposite to the heat generation system. The first insulating layer has a thermal conductivity in a second range below a first range. The thermal chamber assembly also includes a first end and a second end opposite the first end in length relative to the first insulating layer. A tenon extends from the first end. A groove extends into the second end.

[0085] The thermal chamber assembly also includes a radiation blocking layer connected to the first insulating layer between the first insulating layer and the radiation plate layer. The radiation blocking layer has a thermal conductivity within a first range.

[0086] Each of the wall sections may further include a ventilation cavity assembly connected to the thermal cavity assembly. The ventilation cavity assembly includes a second insulating layer connected to the first insulating layer opposite to the radiation blocking layer. The second insulating layer has a second range of thermal conductivity.

[0087] The ventilation cavity assembly also includes a gas barrier layer, which is connected to the second insulating layer opposite to the first insulating layer. The gas barrier layer and the second insulating layer are connected at a first distance to establish a first gas layer between the second insulating layer and the gas barrier layer.

[0088] The ventilation cavity assembly also includes an outer layer, which is connected to the gas barrier layer opposite to the second insulating layer. The outer layer and the gas barrier layer are connected at a second distance to establish a second gas layer between the gas barrier layer and the outer layer.

[0089] Step 802 involves transporting multiple wall sections to the construction site. The wall sections can be manufactured on-site and then transported to the construction site by train, truck, etc. Cranes, elevators, and other equipment can lift the multiple wall sections to their approximate final position before proceeding with the method.

[0090] Step 804 involves connecting the multiple wall segments by connecting the tongue of a first wall segment to a groove in a second wall segment. The tongue fits within the groove to create a tight fit between the multiple wall segments. A sealant or other adhesive can be used to seal the joints between the multiple wall segments. Other components can be added to the multiple wall segments or used to reinforce the joint between them.

[0091] Figure 9 A thermal insulation method according to one or more embodiments is shown. Figure 9 The method can be implemented using one or more of the wall segments, such as... Figures 1 to 7 The wall assembly (100) shown.

[0092] Step (900) involves constructing a building that includes walls. The walls may be... Figure 1 The wall assembly (100) shown is illustrated. Therefore, the wall may include a thermal chamber assembly. The thermal chamber assembly includes a radiating plate layer having a first range of thermal conductivity. The thermal chamber assembly also includes a heat generation system connected to the radiating plate layer.

[0093] The thermal chamber assembly also includes a first insulating layer connected to the radiating plate layer opposite to the heat generation system. The first insulating layer has a thermal conductivity in a second range below a first range. The thermal chamber assembly also includes a first end and a second end opposite the first end in length relative to the first insulating layer. A tenon extends from the first end. A groove extends into the second end.

[0094] The thermal chamber assembly also includes a radiation blocking layer connected to the first insulating layer between the first insulating layer and the radiation plate layer. The radiation blocking layer has a thermal conductivity within a first range.

[0095] The wall may also include a ventilation cavity assembly connected to the thermal cavity assembly. The ventilation cavity assembly includes a second insulating layer connected to the first insulating layer opposite to the radiation blocking layer. The second insulating layer has a second range of thermal conductivity.

[0096] The ventilation cavity assembly also includes a gas barrier layer, which is connected to the second insulating layer opposite to the first insulating layer. The gas barrier layer and the second insulating layer are connected at a first distance to establish a first gas layer between the second insulating layer and the gas barrier layer.

[0097] The ventilation cavity assembly also includes an outer layer, which is connected to the gas barrier layer opposite to the second insulating layer. The outer layer and the gas barrier layer are connected at a second distance to establish a second gas layer between the gas barrier layer and the outer layer.

[0098] Step 902 includes generating heat or cooling using a heat generation system and directing the heat or cooling toward the radiant panel layer. For example, a heated or cooled liquid can be pumped through pipes in the heat generation system. The heated or cooled liquid achieves heat transfer toward the radiant panel layer. In another example, a heated or cooled gas (e.g., air) can be pumped into the gap space between the interior finish layer and the radiant panel layer (or into other gap spaces located in the heat generation chamber assembly of the wall assembly). The heated or cooled gas achieves heat transfer toward the radiant panel layer.

[0099] In yet another instance, electrical components may constitute part or all of the heat generation system. In this case, electricity can be generated and transferred to the electrical components. In response, the electrical components generate heat. The heat from the electrical components is then transferred towards the radiating plate layer.

[0100] Heat generation systems can also operate based on different physical principles. For example, induction heating systems can be used to heat liquids stored in pipes within the heat generation system. The liquid then heats the pipes. The heat emitted from the pipes is transferred towards the radiant heat exchanger. Depending on the type of heat generation system used, other heat transfer methods are also possible.

[0101] Although Figure 8 and Figure 9 The steps in the flowchart are presented and described in sequence, but at least some of the steps may be performed in a different order, may be combined or omitted, and some of the steps may be performed in parallel.

[0102] When used with respect to measurable physical properties, the term "about" refers to an engineering tolerance anticipated or determined by an engineer or manufacturing technician skilled in the art. The precise quantification of an engineering tolerance depends on the product being manufactured and the technical property being measured. For example, in one embodiment, if the values ​​of two angles are within a first predetermined angle range, the two angles may be "about equal," but in another embodiment, if the values ​​of two angles are within a second predetermined angle range, the two angles may also be "about equal." A person skilled in the art can assess what constitutes an acceptable engineering tolerance for a particular product and, therefore, can assess how to determine the variance of the measured values ​​considered by the term "about."

[0103] As used herein, unless otherwise stated, the term "connected to" is considered to have at least two meanings. In the first meaning, "connected to" means that component A is separated from component B at least at some point, but is then joined to component B in an arrangement that is fixed or removably attached. In the second meaning, "connected to" means that component A can be integrally formed with component B. Thus, for example, the bottom of a pot is "connected to" the walls of the pot. The term "connected to" can be interpreted as the bottom and walls being separate components that are snap-fitted together, welded, or otherwise fixedly or removably attached to each other. However, when the bottom and walls are continuously formed together as a rigid shell body, the bottom and walls can be considered "connected".

[0104] Furthermore, the term "directly connected" means that component A and component B are connected adjacent to each other. For example, component A and component B may share a common contact point in at least one area of ​​the two components. However, the common contact point can be a connector (e.g., a bolt, screw, etc.), in which case component A can be "directly connected" to component B without direct contact between the surfaces of component A and component B. However, in any case, if component A and component B are "directly connected" to each other, there are no intermediate parts between component A and component B other than possible connectors.

[0105] The accompanying drawings illustrate diagrams of embodiments according to this disclosure. The embodiments in the drawings can be combined and may include or be included within features and embodiments described in other drawings of this application. The features and elements in the drawings, individually and in combination, are improvements to the technique of building walls. As shown in the drawings, various elements, systems, components, and steps illustrated in the drawings may be omitted, repeated, combined, and / or changed. Therefore, the scope of this disclosure should not be considered limited to the specific arrangements shown in the drawings.

[0106] In this application, ordinal numbers (e.g., first, second, third, etc.) may be used as adjectives for elements (i.e., any noun in this application). Unless explicitly disclosed, such as by using the terms “before,” “after,” “single,” and other such terms, the use of ordinal numbers does not imply or create any particular ordering of elements, nor does it limit any element to a single element. Rather, the use of ordinal numbers is for distinguishing elements. For example, a first element is different from a second element, and a first element may encompass more than one element and may be after (or before) the second element in the order of elements.

[0107] Additionally, unless otherwise explicitly stated, the word "or" is "inclusive or" and therefore includes "and". Furthermore, unless otherwise explicitly stated, items connected by "or" can include any combination of items with any number of each item.

[0108] In the foregoing description, numerous specific details have been set forth to provide a more thorough understanding of one or more embodiments. However, it will be apparent to those skilled in the art that one or more embodiments can be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description. Furthermore, other embodiments not explicitly described above may be designed without departing from the scope of one or more embodiments disclosed herein. Therefore, the scope of one or more embodiments should be limited by the appended claims.

Claims

1. A wall comprising: A thermal chamber assembly comprising: A radiating plate layer, the radiating plate layer comprising a first range of thermal conductivity. A heat generation system, the heat generation system being connected to the radiant plate layer, A first insulating layer, connected to the radiating plate layer opposite to the heat generation system, and comprising a second range of thermal conductivity lower than the first range, and A radiation blocking layer, the radiation blocking layer being connected to the first insulating layer between the first insulating layer and the radiation plate layer, the radiation blocking layer comprising the thermal conductivity of the first range; and A ventilation cavity assembly, connected to the hot chamber assembly, and comprising: A second insulating layer, connected to the first insulating layer opposite to the radiation blocking layer, the second insulating layer having a thermal conductivity within the second range. A gas barrier layer, wherein the gas barrier layer and the radiation barrier layer are connected to the second insulating layer opposite to each other, wherein the gas barrier layer and the second insulating layer are connected at a first distance to establish a first gas layer between the second insulating layer and the gas barrier layer, and An outer layer is connected to the gas barrier layer opposite to the second insulating layer, wherein the outer layer is connected to the gas barrier layer at a second distance to establish a second gas layer between the gas barrier layer and the outer layer.

2. The wall according to claim 1, further comprising: An interior cladding wall layer, which is connected to the radiant panel layer and faces the interior of the building, wherein the heat generation system is located between the interior cladding wall layer and the radiant panel layer.

3. The wall according to claim 1 or claim 2, wherein the radiating plate layer comprises corrugated aluminum.

4. The wall according to any one of claims 1 to 3, wherein the thermal conductivity of the first range comprises a thermal conductor, and the thermal conductivity of the second range comprises a thermal insulator.

5. The wall according to any one of claims 1 to 4, wherein the first insulating layer comprises: The first end and the second end, which is opposite to the first end in length relative to the first insulating layer. Tenon, the tenon extending from the first end, and A groove that extends into the second end.

6. The wall according to any one of claims 1 to 5, wherein the heat generation system comprises a liquid heating system.

7. The wall according to any one of claims 1 to 6, wherein the heat generation system comprises an electric heating system.

8. The wall according to any one of claims 1 to 6, wherein the heat generation system comprises an air conditioning system.

9. The wall according to any one of claims 1 to 8, further comprising: A cork strip, which is disposed around the periphery of the first insulation layer between the first insulation layer and the second insulation layer.

10. The wall according to any one of claims 1 to 9, further comprising: A head frame that extends from the second insulating layer.

11. The wall according to any one of claims 1 to 10, further comprising: A first tube is connected to and disposed within the second insulating layer.

12. The wall according to claim 11, wherein the first tube is disposed relative to the direction of gravity along the height of the second insulating layer.

13. The wall according to claim 12, further comprising: A second tube, which is connected to and disposed within the second insulating layer, is disposed opposite to the first tube and along the height of the second insulating layer.

14. The wall according to any one of claims 1 to 13, further comprising: A bottom frame is disposed around the second insulating layer, wherein the bottom frame is disposed at the bottom of the second insulating layer relative to the direction of gravity.

15. The wall according to any one of claims 1 to 14, further comprising: A gasket, the gasket being connected to the second insulating layer and the gas barrier layer, wherein the gasket establishes the first distance.

16. The wall according to any one of claims 1 to 15, further comprising: Multiple clips connect the gas barrier layer to the outer frame. The outer layer is connected to the outer frame; and The plurality of clamps establish the second distance.

17. The wall according to claim 16, further comprising: The first set of insulating blocks is disposed between at least some of the clamps in the plurality of clamps, the gas barrier layer and the outer layer.

18. The wall according to claim 17, further comprising: The second set of insulating blocks is disposed between the second insulating layer and the gas barrier layer.

19. A manufacturing method comprising: Manufacture a plurality of wall segments, each of the plurality of wall segments comprising: A thermal chamber assembly comprising: A radiating plate layer, the radiating plate layer comprising a first range of thermal conductivity. A heat generation system, the heat generation system being connected to the radiant plate layer, A first insulating layer, connected to the radiant plate layer opposite to the heat generation system, and comprising: The thermal conductivity of the second range is lower than that of the first range. The first end and the second end, which is opposite to the first end in length relative to the first insulating layer. Tenon, the tenon extending from the first end, and A groove, the groove extending into the second end, and A radiation blocking layer, wherein the radiation blocking layer is connected to the first insulating layer between the first insulating layer and the radiation plate layer, and the radiation blocking layer comprises a thermal conductivity of the first range; as well as A ventilation cavity assembly, connected to the hot chamber assembly, and comprising: A second insulating layer, connected to the first insulating layer opposite to the radiation blocking layer, the second insulating layer having a thermal conductivity within the second range. A gas barrier layer is connected to a second insulating layer opposite to a first insulating layer, wherein the gas barrier layer and the second insulating layer are connected at a first distance to establish a first gas layer between the second insulating layer and the gas barrier layer. An outer layer is connected to the gas barrier layer opposite to the second insulating layer, wherein the outer layer is connected to the gas barrier layer at a second distance to establish a second gas layer between the gas barrier layer and the outer layer; Transport the multiple wall sections to the construction site; as well as The plurality of wall sections are connected by connecting the tenon of the first wall section to the groove of the second wall section.

20. A method for thermal insulation, comprising: Constructing a building that includes walls, wherein the walls include: A thermal chamber assembly comprising: A radiating plate layer, the radiating plate layer comprising a first range of thermal conductivity. A heat generation system, the heat generation system being connected to the radiant plate layer, A first insulating layer, connected to the radiant plate layer opposite to the heat generation system, and comprising: The thermal conductivity of the second range is lower than that of the first range. The first end and the second end, which is opposite to the first end in length relative to the first insulating layer. Tenon, the tenon extending from the first end, and A groove, the groove extending into the second end, and A radiation blocking layer, wherein the radiation blocking layer is connected to the first insulating layer between the first insulating layer and the radiation plate layer, and the radiation blocking layer comprises a thermal conductivity of the first range; as well as A ventilation cavity assembly, connected to the hot chamber assembly, and comprising: A second insulating layer, connected to the first insulating layer opposite to the radiation blocking layer, the second insulating layer having a thermal conductivity within the second range. A gas barrier layer is connected to a second insulating layer opposite to a first insulating layer, wherein the gas barrier layer and the second insulating layer are connected at a first distance to establish a first gas layer between the second insulating layer and the gas barrier layer. An outer layer is connected to the gas barrier layer opposite to the second insulating layer, wherein the outer layer is connected to the gas barrier layer at a second distance to establish a second gas layer between the gas barrier layer and the outer layer; as well as The heat generation system generates heat or cooling, and directs the heat or cooling toward the radiant plate layer.

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