Building Bracket with Foam Embedding for Thermal Insulation
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Solution Overview
Problem
Current construction methods fail to effectively conserve energy, prevent air infiltration, condensation, and moisture migration in buildings, particularly due to inadequate thermal insulation and leaky building envelopes.
Innovation Solution
A building module system featuring a bracket with a platform and sides, where rigid brackets are affixed to a construction panel and covered with spray polyurethane foam, creating an air/water barrier and resisting moisture buildup, while allowing for adjustable attachment to uneven surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If foam insulation board is applied followed by siding, then insulation capability is improved, but air/water barrier effectiveness and moisture resistance are insufficient
Solution Approach 1:
The patent combines foam insulation board with a separate air/water barrier membrane and siding system to create a composite wall assembly. The foam insulation provides thermal insulation while the integrated barrier membrane prevents air infiltration and moisture migration, resolving the contradiction between insulation and barrier effectiveness.
Solution Approach 2:
The patent applies different materials with specific properties to different layers of the wall assembly: foam insulation for thermal performance, barrier membrane for air/water protection, and siding for exterior durability. Each layer performs its specific function optimally, addressing both insulation and barrier requirements.
2Strength
If rigid brackets are used for structural support, then strength is improved, but thermal conductivity increases reducing insulation effectiveness
Solution Approach 1:
The rigid brackets are strategically positioned only at structural support points rather than continuously across the entire wall assembly. This localized approach provides necessary structural strength while minimizing the thermal bridge effect, as the brackets occupy minimal area relative to the overall insulation surface.
Solution Approach 2:
The patent separates the structural support function (performed by brackets) from the continuous insulation layer. By extracting structural support to discrete bracket elements rather than using continuous rigid framing, the design maintains strength where needed while preserving insulation continuity in the remaining areas.
3Loss of energy
If building envelope is made tight for energy conservation, then energy efficiency is improved, but moisture buildup and condensation risk increase
Solution Approach 1:
The patent introduces an air/water barrier membrane as an intermediary layer between the interior and exterior environments. This barrier selectively prevents harmful air infiltration and moisture migration while allowing the building to maintain a tight thermal envelope for energy efficiency. The barrier acts as a mediator that protects against moisture-related harmful effects.
Solution Approach 2:
The building envelope is designed with different properties at different layers: the interior side maintains tightness for energy conservation while the exterior side incorporates breathable characteristics through the barrier membrane and siding assembly, allowing moisture vapor to escape while preventing liquid water infiltration.
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 system provides enhanced insulation, energy efficiency, and a weather-tight envelope by embedding brackets with foam, reducing thermal conductivity and enhancing structural rigidity, while accommodating various surface types and orientations.
Implementation Method 1
applying a rigid, closed-cell, spray polyurethane foam or adhesive contiguous to substantially cover the planar surface of the inner construction panel and fill and surround and/or embed at least a major portion of the one or more brackets
Implementation Method 2
enhanced insulation, energy efficiency, and a weather-tight envelope by embedding brackets with foam, reducing thermal conductivity
Data Source
AI summary
A bracket for a building module. The bracket has a platform bearing a substantially planar surface, first and second sides appending from the platform away from the planar surface, and a bottom panel extending from the first side to the second side. Each of the first and second sides defines a proximal portion and a distal portion therealong. The distal portion of the first side is inwardly directed toward the distal portion of the second side. There is also a building module, a method for making a building module, and a method for constructing a building.