Building Module With Embedded Brackets And Structural Foam
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Solution Overview
Problem
Current construction methods fail to effectively combine high strength, insulation capability, air/water barrier, and moisture resistance in building envelopes, leading to energy losses and issues with air infiltration, condensation, and moisture migration.
Innovation Solution
A building module comprising a rigid inner construction panel with affixed brackets and a sprayed rigid, closed-cell structural foam or adhesive matrix, where the brackets have a planar surface facing away from the panel, providing a combination of structural support, insulation, and air/water barrier functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If foam insulation board and siding are applied sequentially, then insulation capability is improved, but air/water barrier effectiveness and moisture resistance deteriorate
Solution Approach 1:
The patent combines the insulation board and siding into a single integrated panel structure where the insulation material is bonded directly to the siding substrate, eliminating the gap between layers and creating a unified air/water barrier system that maintains both insulation performance and barrier effectiveness
Solution Approach 2:
The integrated panel uses composite construction with an outer siding layer bonded to an inner insulation core, creating a multi-functional material system that simultaneously provides structural integrity, weather resistance, and thermal insulation in a single component
2Ease of manufacture
If traditional insulation methods are used, then simplicity of construction is improved, but moisture buildup and condensation resistance deteriorate
Solution Approach 1:
The patent incorporates a vapor retarder film or coating within the integrated panel structure that selectively blocks moisture vapor transmission while allowing the panel to maintain its simple installation process, preventing condensation and moisture accumulation behind the siding
Solution Approach 2:
The integrated panel acts as an intermediary barrier between the exterior environment and the building interior, combining multiple protective functions (weather resistance, moisture control, insulation) in a single installed component that simplifies construction while actively preventing harmful moisture effects
3Strength
If rigid brackets are affixed to construction panels, then structural support is improved, but insulation continuity deteriorates
Solution Approach 1:
The patent nests the bracket mounting system within the integrated panel structure itself, with brackets attached to the panel's internal framework rather than penetrating through the insulation layer, allowing structural support while maintaining continuous insulation coverage
Solution Approach 2:
The patent provides structural support only at specific localized points where brackets are mounted on the panel framework, rather than requiring continuous structural elements throughout, thereby maintaining insulation continuity in the spaces between bracket locations while providing adequate structural support where needed
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 enhances energy efficiency by reducing energy losses, preventing air infiltration and moisture buildup, while maintaining structural integrity and allowing for ventilation through strategically placed vents.
Implementation Method 1
a sprayed rigid, closed-cell structural foam (e.g., a sprayed or foam-in-place foam) or adhesive contiguous to and substantially covering the planar surface of the construction panel and contacting and embedding at least a major portion of the one or more brackets
Implementation Method 2
sprayed rigid, closed-cell structural foam
Data Source
AI summary
A building module. The building module has a rigid inner construction panel defining a planar surface thereon; one or more rigid brackets each affixed by one or more mechanical fasteners to the planar surface of the construction panel; a rigid, closed-cell, spray foam or an adhesive matrix contiguous to and substantially covering the planar surface of the construction panel and contacting and embedding at least a major portion of the one or more brackets. Each of the one or more brackets bears a planar surface facing substantially away from the planar surface of the construction panel. The surface area of the planar surface of each of the one or more brackets is substantially smaller than the surface area of the planar surface of the construction panel to which it is affixed. There are also other embodiments of building modules. There are also other embodiments of brackets useful in building modules. There are also other embodiments for making building modules.