Composite Panel with Embedded Reinforcing Element
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Solution Overview
Problem
There is a need to minimize energy costs associated with cladding buildings, particularly in the context of insulating panels, as existing solutions do not effectively address the balance between energy efficiency and structural integrity.
Innovation Solution
A composite panel design comprising a first and second sheet with an insulating body and a reinforcing element, where the reinforcing element is embedded within the insulating body, enhancing structural strength and reducing the need for additional framing, and featuring insulating tape between the sheets to prevent cold bridging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the insulating body is made thicker to improve thermal insulation, then energy efficiency is improved, but the structural strength and stability of the panel deteriorates
Solution Approach 1:
The patent employs a composite structure combining metal sheets (for strength) with foam insulating material (for thermal insulation). This composite construction allows the panel to achieve both high energy efficiency and structural strength simultaneously, resolving the contradiction between thick insulation and structural integrity.
Solution Approach 2:
A reinforcing element acts as an intermediary component embedded within the insulating body. This mediator provides the necessary structural strength and stability that would otherwise be lost when using thick insulating material, allowing the panel to maintain both thermal efficiency and structural integrity.
2Strength
If a reinforcing element is added to the insulating body to improve structural strength, then structural integrity is improved, but the thermal insulation performance deteriorates due to cold bridging
Solution Approach 1:
An insulating layer acts as a thermal intermediary between the reinforcing element and the metal sheets. This intermediary prevents direct thermal contact (cold bridging) while allowing the reinforcing element to provide structural strength, thus maintaining both structural integrity and thermal insulation performance.
Solution Approach 2:
The harmful thermal conduction path is extracted or removed from the system by introducing the insulating layer that breaks the thermal bridge between the metal sheets and reinforcing element, eliminating the negative effect while preserving the structural function.
3Strength
If traditional separate framing is used to provide structural support, then structural strength is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The reinforcing element is merged directly into the insulating body during panel manufacturing, creating an integrated structure. This eliminates the need for separate framing components and assembly steps, reducing device complexity and manufacturing cost while maintaining structural strength.
Solution Approach 2:
The reinforcing element serves multiple functions simultaneously: it provides structural strength, maintains panel rigidity, and works in conjunction with the insulating layer to prevent cold bridging. This multi-functionality reduces the need for additional specialized components.
4Strength
If the reinforcing element is placed on the outer surface of the panel to provide structural support, then structural strength is improved, but the insulation performance deteriorates and condensation risk increases
Solution Approach 1:
The reinforcing element is nested within the insulating body rather than placed on the outer surface. This nested configuration ensures the reinforcing element is surrounded by thermal insulation on all sides, preventing cold bridging and condensation while still providing the necessary structural 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 enhanced structural strength and reduced energy costs by minimizing the requirement for steel framing and on-site erection time, while maintaining energy efficiency through effective insulation.
Implementation Method 1
allowing the liquid foam reactants to expand to form a foam insulating body between the first and second sheets
Implementation Method 2
foam insulating body
Implementation Method 3
insulating tape between the reinforcing element and the first and second sheets
Data Source
AI summary
An insulating panel (1) comprises a first sheet (2), a second sheet (3) with an insulating foam (4) therebetween. The foam may, for example be a polyurethane foam, polyisocyanurate foam or a phenolic foam. The first and second sheets (2, 3) are metal such as steel, for example a galvanised or coated sheet. At least one reinforcing element (20) is provided within the insulating foam (body (4) and extends between the first and second sheets (2, 3). The reinforcing element (20) extends longitudinally along at least part of the length of the panel (1). For enhanced structural strength there are at least two reinforcing elements (20) which are spaced-apart between the side marginal edges of the panel (1). The reinforcing element (20) comprises a first flange (21), a second flange (22) and a web (23) extending between the flanges. The reinforcing element (20) is adapted to interengage with the insulating foam body (4) during manufacture. The element (20) has a plurality of through holes (25) at least in the web (23) thereof to facilitate passage of reacting foam. The web may also have keying features such as ribs (29) or the like. The ribs (29) may be pressed out to enhance the structural strength/stiffness of the elements (27). Similarly, the metal in the region of the holes (25) may be provided with pressed ribs to enhance structural strength.