Composite Connection System for Thermal Break Panels
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Solution Overview
Problem
Existing connection systems for prefabricated thermal break panels often compromise structural stability due to concentrated strain, induce high thermal expansion stresses, and create thermal bridges, while being costly and complex, and may fail under increased temperature conditions, especially in fires.
Innovation Solution
A connection system comprising C-shaped and U-shaped hooking elements made of fibre-glass reinforced thermosetting plastic, designed to anchor into the metallic reinforcement mesh within the panels, distributing loads evenly and accommodating thermal expansion without inducing additional stress, with low thermal conductivity and fire resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal connection elements are used, then structural strength is improved, but thermal conductivity increases creating thermal bridges
Solution Approach 1:
The connection element uses a composite structure with a central metal core rod (aluminum or stainless steel) for mechanical strength, and an outer coating layer (polymer, ceramic, or glass) for thermal insulation. This composite design allows the element to simultaneously achieve high tensile strength while maintaining low thermal conductivity, thus preventing thermal bridges between the inner and outer concrete layers.
2Ease of manufacture
If connecting plugs made from thermoplastic material are used, then ease of manufacture is improved, but reliability deteriorates under high temperature conditions
Solution Approach 1:
The connection element combines a metal core rod that maintains structural integrity at high temperatures with a polymer coating that provides corrosion resistance and thermal insulation. The metal core ensures reliability under fire conditions while the polymer coating can be applied through standard manufacturing processes, maintaining ease of manufacture.
Solution Approach 2:
The invention changes the material parameters by selecting a metal core with high melting point and maintaining structural properties at elevated temperatures, while the outer coating is selected for its thermal stability and resistance to degradation. This parameter optimization ensures the connection element remains reliable under high temperature conditions such as fires.
3Strength
If connection systems transfer thermal expansion stresses directly to the structural part, then connection strength is improved, but the structural part experiences high strain
Solution Approach 1:
The insulating coating layer acts as an intermediary between the metal core and the concrete layers, providing a compliant interface that can accommodate differential thermal expansion. The metal core maintains connection strength while the coating layer absorbs and distributes thermal expansion stresses, preventing direct transfer of high strains to the structural concrete parts.
4Loss of energy
If the panel thickness is reduced to improve heat efficiency, then energy loss is reduced, but the connection system becomes more critical for structural stability
Solution Approach 1:
The use of composite connection elements with high strength-to-weight ratio allows for reduced panel thickness while maintaining structural stability. The metal core provides the necessary mechanical strength to support thinner panel configurations, while the insulating coating maintains thermal performance, enabling both reduced heat loss and preserved structural stability.
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 ensures structural integrity, minimizes thermal stress, maintains low thermal conductivity, and is cost-effective, adaptable to various panel sizes and shapes, and resistant to temperature fluctuations and fires, eliminating the need for transmittance calculations.
Implementation Method 1
low thermal conductivity
Implementation Method 2
accommodating thermal expansion without inducing additional stress
Data Source
AI summary
The present invention describes a connection system for prefabricated panels of the type comprising at least two outer concrete layers (12, 14), provided with metallic reinforcement (18), and an intermediate layer (16) made of heat-insulating material, arranged between the two outer concrete layers (12, 14). The system comprises a plurality of plate-like connection elements (10) having such a length (L) as to allow them to extend, in an orthogonal direction with respect to the panel's development plan, through the heat-insulating layer (16) and to partially penetrate inside the outer concrete layers (12, 14). Each connection element (10) is provided, at two opposed terminal ends, with respective hooking means (22, 24) to the outer concrete layers (12, 14). At least one (24) of the hooking means provided at the opposed terminal ends of each connection element (10) is made up of two distinct C-shaped edges (24A, 24B), side by side and parallel to each other. The C-shaped edges (24A, 24B) are capable of hooking onto respective bars (20) provided on the metallic reinforcement (18) of at least one (12) of the panel's outer concrete layers.