Insulated Cementitious Building Panel Without Thermal Bridges
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Solution Overview
Problem
Existing prefabricated insulated building panels face limitations such as size constraints, excessive weight, and thermal bridging due to fasteners, which affect load-bearing capacity, joint efficiency, and moisture management in building construction.
Innovation Solution
A prefabricated insulated building panel design featuring a sheet of rigid insulating material with composite cementitious layers bonded on both sides, where the cementitious layers are supported by bonding action alone, eliminating thermal bridges and incorporating channels for moisture management and conduit functions, allowing for larger panel sizes and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If precast concrete sandwich panels are used to increase load-bearing capacity and reduce panel size, then load-bearing capacity is improved, but weight increases excessively
Solution Approach 1:
The patent uses composite cementitious material layers bonded to rigid insulating material to create a hybrid structure that combines the load-bearing capacity of concrete with the lightweight insulation properties of foam core, achieving both strength and weight reduction
Solution Approach 2:
The patent changes the material parameters by using cured cementitious material with specific thickness ranges (0.5-2 inches) bonded to insulation, transforming the panel from heavy concrete construction to a lighter composite structure that maintains structural integrity
2Area of stationary object
If traditional SIP panels with wood or concrete board skins are used, then panel size is limited to mass production sheet dimensions, but this requires multiple joints and additional exterior layers
Solution Approach 1:
The patent segments the panel into distinct functional layers (inner cementitious layer, insulation core, outer cementitious layer) that can be manufactured separately and bonded together, allowing for larger panel sizes while maintaining manufacturing efficiency
Solution Approach 2:
The cementitious layers serve multiple functions simultaneously: structural skin, exterior finish, and interior finish, eliminating the need for separate OSB/concrete board layers and gypsum sheetrock, thereby reducing overall panel complexity
3Strength
If fasteners are used to connect cementitious layers to insulation, then bonding strength is improved, but thermal bridges are created
Solution Approach 1:
The patent replaces mechanical fastening systems with chemical bonding through cured cementitious material that adheres directly to the insulation surface, eliminating the need for metal fasteners that create thermal bridges while maintaining structural connection strength
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 provides improved load-bearing capacity, reduced weight, enhanced thermal insulation, and efficient moisture management, enabling larger panel sizes with fewer joints, increased labor efficiency, and integration of plumbing and electrical conduits, while maintaining thermal performance.
Implementation Method 1
a first thickness of the cured composite cementitious material from the ledge surfaces to the outer face of the inner layer being greater than the thickness of the cured composite cementitious material at the first face of the rigid insulating material so that the bonding action effected during curing of the composite cementitious material to the rigid insulating material is alone able to carry a weight of the cured composite cementitious material
Implementation Method 2
The channels provide the wall panel with an air space between an exterior 'rain screen' and the rigid insulating material, which has the effect of allowing the panel to 'pressure equalize' which when exposed to high wind conditions with rain prevents moisture from being drawn into the building
Data Source
Figure 1
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Figure 3~5
AI summary
A prefabricated insulated building panel features a sheet of rigid thermally insulating material, an inner structural layer connected to one face of the insulating material, and an outer layer of cured composite cementitious material connected to an opposite second face of the rigid insulating material with a thickness allowing the cured composite cementitious layer to be supported at the insulating material by bonding action therewith. The panel also features channels at the interface between the composite cementitious outer layer and the insulating material formed by grooves in the second face of the insulating material extending to a periphery of the panel. These channels afford pressure equalization and moisture drainage capabilities to the panel. Additionally, the inner structural layer comprises a layer of cured composite cementitious material bonded to the insulating material, which has a thickened edge portion along the periphery of the panel compared to strengthen the panel.