Building Module with Embedded Brackets and Spray Foam Insulation
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Solution Overview
Problem
Existing 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 comprising a rigid inner construction panel with affixed brackets and a sprayed rigid, closed-cell structural foam or adhesive matrix that embeds the brackets, providing a high-strength, insulating, and moisture-resistant barrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If foam insulation board followed by siding is applied to building exteriors, then insulation capability is improved, but air infiltration and moisture migration prevention are insufficient
Solution Approach 1:
The patent combines multiple functions into a single integrated building module assembly: structural support (brackets), thermal insulation (spray foam), air barrier, and moisture protection are merged into one system rather than applied as separate layers, creating a reliable multi-functional envelope that prevents air infiltration and moisture migration while maintaining energy efficiency
Solution Approach 2:
The building module uses composite construction combining rigid brackets (structural material), spray foam insulation (thermal and air barrier material), and siding materials (protective exterior material) into a unified assembly that delivers superior performance in both insulation and barrier functions simultaneously
2Ease of manufacture
If traditional building envelope methods are used, then construction simplicity is maintained, but energy conservation and moisture prevention are inadequate
Solution Approach 1:
The building envelope is divided into modular building modules that can be manufactured and installed as discrete units, maintaining construction simplicity through standardization while incorporating advanced insulation and barrier technologies within each module to achieve superior energy conservation and moisture prevention
3Strength
If rigid brackets are affixed to construction panels with spray foam embedding, then structural strength and insulation are improved, but device complexity increases
Solution Approach 1:
The spray foam serves multiple functions simultaneously: it acts as structural adhesive bonding brackets to panels, provides thermal insulation, creates an air barrier, and embeds the brackets for structural support, thereby improving strength without proportionally increasing complexity through multi-functional material use
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, reduces air infiltration, and prevents moisture buildup by creating a continuous air and water barrier while maintaining structural integrity and allowing for ventilation, thus improving the overall building envelope.
Implementation Method 1
sprayed rigid, closed-cell structural foam (such as a sprayed or foam-in-place foam) or an adhesive contiguous to the construction panel and contacting and surrounding and/or embedding at least a major portion of the one or more brackets
Implementation Method 2
rigid, closed-cell spray foam or an adhesive matrix contiguous to and substantially covering the planar surface of the construction panel
Implementation Method 3
sprayed rigid, closed-cell structural foam... contacting and surrounding and/or embedding at least a major portion of the one or more brackets
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 inner construction panel; a rigid, closed-cell, spray foam or adhesive matrix contiguous to and substantially covering the planar surface of the construction panel and filling and surrounding and/or 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 inner 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 is also a method for making a building module, a method for constructing a building using the building module, and brackets useful in the building module.