Composite Insulation Clips for Thermal Break and Corrosion Control
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Solution Overview
Problem
Conventional metal wall and roof assemblies experience reduced lifespan due to thermal cycling-induced damage and corrosion from metal-to-metal contact, leading to inefficient thermal insulation and increased heat transfer.
Innovation Solution
An insulation system comprising clips made of composite materials, such as resin and fibers, that are disposed between insulation panels to create a thermal break, preventing direct contact and mitigating heat transfer by using notches and securing mechanisms to secure the panels effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal anchors and fasteners are used to secure insulation panels, then the panels are securely attached to the structure, but thermal bridging occurs and metal-to-metal contact causes corrosion and reduced lifespan
Solution Approach 1:
The patent introduces composite clips as an intermediary material between metal components and insulation panels. These clips are made of non-metallic composite materials that provide mechanical attachment while eliminating thermal conductivity and corrosion pathways. The clips act as a mediator that maintains structural integrity without creating thermal bridges or corrosion risks between dissimilar metals.
Solution Approach 2:
The patent utilizes composite materials for the clips that combine the benefits of structural strength with thermal insulation properties. These composite clips replace traditional metal fasteners, providing both mechanical securing functionality and thermal break capabilities simultaneously, thus resolving the contradiction between secure attachment and thermal bridging.
2Loss of energy
If metal skins are bonded to insulation panels in a factory, then thermal efficiency is improved through continuous insulation, but metal-to-metal contact creates thermal pathways and reduces system durability
Solution Approach 1:
The composite clips serve as intermediary elements that interrupt the continuous metal pathways. By positioning these non-conductive clips at critical attachment points, the system maintains insulation continuity while breaking thermal bridges that would otherwise conduct heat between exterior and interior metal skins.
3Ease of operation
If clips with width equal to notches are used, then precise positioning and tight fit are achieved, but manufacturing precision requirements increase
Solution Approach 1:
The patent specifies that the clip width substantially equals the notch width, creating a tight-fit relationship. This parameter matching ensures precise positioning during installation while the tolerance stack-up is managed through coordinated manufacturing of both clips and notches, balancing positioning accuracy with manufacturability.
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 effectively reduces thermal bridging, enhances insulation efficiency, and prolongs the lifespan of the assembly by eliminating metal-to-metal contact, thereby maintaining a consistent interior temperature and minimizing corrosion.
Implementation Method 1
The plurality of clips are comprised of a composite material to mitigate heat transfer from the bottom end of the plurality of clips to the top end of the plurality of clips
Data Source
AI summary
A system includes a plurality of a clip, the clip comprises a securing mechanism, a first side, a second side, a bottom end, and a top end. During installation of an insulation system a plurality of the clip are coupled to a support beam and disposed within a plurality of notches of a second insulation board. The plurality of clips further include a width that is substantially equal to a width of the plurality of notches such that during the installation of the insulation system the plurality of clips are disposable within the plurality of notches to allow a second side of a first insulation board to contact a first side of the second insulation board and the securing mechanism secures a back surface of the first insulation board against the plurality of clips.