Composite Bracket Member for Thermal Break
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Solution Overview
Problem
Conventional metal wall and roof assemblies experience reduced lifespan due to thermal cycling and material oxidation from metal-to-metal contact, leading to thermal bridging and corrosion, which affects thermal efficiency and integrity.
Innovation Solution
A bracket assembly with an elongated bracket member comprising a plurality of fibers within a resin matrix, where the fibers extend through the bracket member's walls and support members, preventing direct metal-to-metal contact and providing a thermal break while maintaining structural integrity through pultrusion and clamping mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal skins are bonded to insulated panel core with metal anchors and fasteners, then structural integrity is achieved, but thermal bridging occurs due to metal-to-metal contact
Solution Approach 1:
The patent introduces a non-metallic bracket member as an intermediary component between the exterior and interior metal skins. This bracket member, made of composite material or thermally broken material, replaces direct metal-to-metal contact points (anchors and fasteners) while still providing the necessary structural support and attachment functionality, thereby eliminating thermal bridging pathways.
Solution Approach 2:
The bracket member is constructed from composite materials that combine structural strength with thermal insulation properties. This composite construction allows the single component to simultaneously provide mechanical support for holding the metal skins together while maintaining thermal break functionality to prevent heat transfer.
2Stability of the object's composition
If metal anchors and fasteners are used to bond metal skins, then assembly stability is achieved, but material oxidation and corrosion occur over time
Solution Approach 1:
The non-metallic bracket member serves as a mediator that eliminates direct contact between dissimilar metals (such as steel anchors with aluminum skin or aluminum fasteners with galvanized steel). By introducing this intermediate composite component, the patent prevents galvanic corrosion and oxidation reactions that would otherwise occur at metal-to-metal interfaces, while still maintaining assembly stability through the bracket's structural design.
3Strength
If multiple dissimilar materials are in contact to provide structural support, then mechanical strength is achieved, but thermal conductivity increases
Solution Approach 1:
The bracket member utilizes composite materials that integrate structural reinforcement (such as fiber fabrics like fiberglass, carbon fiber, or aramid) within a resin matrix. This composite construction provides the necessary mechanical strength to support the metal skin assembly while the resin matrix and air pockets within the composite structure create thermal barriers that reduce thermal conductivity, effectively breaking the thermal bridge.
4Ease of manufacture
If metal components are used throughout the assembly, then ease of manufacture is maintained, but thermal efficiency decreases
Solution Approach 1:
The bracket member can be manufactured using pultrusion processes or other composite manufacturing techniques that are well-established in the building products industry. This allows for efficient production of the thermally broken component without significantly complicating the manufacturing process, while achieving superior thermal efficiency compared to traditional all-metal assemblies.
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, minimizes material oxidation, and enhances structural integrity by maintaining insulation and preventing damage from thermal cycling, even in catastrophic events like fires, while ensuring the cladding remains coupled to the building.
Implementation Method 1
The bracket member has an internal composition that includes at least one fiber fabric embedded within a resin matrix
Implementation Method 2
The plurality of fibers includes at least one fiber fabric embedded within the resin matrix
Data Source
AI summary
A bracket assembly comprising an elongated bracket member and an end wall support member. The elongated bracket member has a body wall having an inner end and an outer end. A first end wall extends from the inner end of the body wall and a second end wall extends from the outer end. The end wall support member is attached to each of the first end wall and the second end wall. The bracket member further comprises a plurality of fibers within a resin matrix. The plurality of fibers includes at least one fiber fabric extending from the first end wall to the second end wall.