Bracket Assembly Composition for Thermal Break Wall Cladding
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Solution Overview
Problem
Conventional metal wall and roof assemblies suffer from thermal bridging due to metal-to-metal contact, leading to reduced durability and increased fire risk, as well as inadequate fire resistance, as evident in recent building fires.
Innovation Solution
A bracket assembly comprising an elongated bracket member with a resin matrix and fibers, sandwiching a non-combustible board between the inner and outer cladding, with insulation and clamping members to prevent direct metal contact and enhance fire resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal skins are bonded to create a foam panel with metal-to-metal contact, then structural integrity is improved, but thermal bridging increases and fire resistance deteriorates
Solution Approach 1:
A non-combustible board is introduced as an intermediary material between the inner and outer metal cladding layers. This board acts as a thermal break and fire barrier, preventing direct metal-to-metal contact while maintaining the structural integrity of the wall assembly. The intermediary layer eliminates thermal bridging pathways without compromising the overall strength of the construction.
Solution Approach 2:
The wall assembly uses a composite construction combining metal cladding layers with a non-combustible board core. This composite structure integrates materials with different thermal and fire properties, creating a system that simultaneously achieves structural strength, thermal efficiency, and fire resistance that neither material could provide alone.
2Strength
If metal anchors and fasteners are used to connect cladding layers, then mechanical coupling is improved, but durability deteriorates due to thermal cycling and corrosion
Solution Approach 1:
The non-combustible board serves as a mediator that separates the metal cladding layers, eliminating direct metal-to-metal contact at fastener locations. This prevents corrosion between dissimilar metals and reduces stress concentration during thermal cycling, thereby improving the durability and reliability of the mechanical connection system.
Solution Approach 2:
The design applies different material properties at different locations: metal cladding for exterior durability, non-combustible board for thermal and fire protection at the connection points, and selective fastening strategies. This local differentiation of material qualities optimizes both mechanical coupling and long-term durability.
3Ease of manufacture
If conventional metal assemblies are used, then ease of manufacture is improved, but fire resistance deteriorates
Solution Approach 1:
The assembly combines conventional metal cladding materials with a non-combustible board core, creating a composite panel system that maintains the ease of manufacture associated with metal assemblies while adding fire resistance. The layered composite structure can be manufactured using standard building techniques and materials.
Solution Approach 2:
The wall assembly is segmented into distinct functional layers: outer metal cladding for weather protection, non-combustible board for fire resistance and thermal break, and inner metal cladding for interior finish. This segmentation allows each layer to be optimized for its specific function while maintaining overall manufacturing efficiency.
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 effectively reduces thermal bridging, enhances structural integrity, and improves fire resistance by maintaining mechanical coupling between the inner and outer cladding even in catastrophic events, such as fires, while preventing the spread of flames.
Implementation Method 1
a non-combustible board... so as to sandwich the non-combustible board between the bracket assembly and the outer cladding
Data Source
AI summary
A wall structure having an inner wall, a bracket member, a non-combustible board, and an outer cladding coupled together and retaining insulation between the inner wall and the outer cladding. The non-combustible board is positioned between the bracket member and the outer cladding.