Corrugated Sheet Insulating Wall Panels Air Gap

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Solution Overview

Problem

Conventional insulating wall panels face challenges in effectively inhibiting heat transfer while maintaining cost-effectiveness and ease of installation, particularly due to the complexity and expense of forming and installing radiant barriers directly adhered to drywall panels.

Innovation Solution

The incorporation of a corrugated sheet between the drywall material and the radiant barrier creates an air gap, using an adhesive to secure the radiant barrier to the corrugated sheet and the drywall, simplifying the installation process and reducing costs by eliminating the need for complex formation techniques.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If radiant barrier is directly adhered to drywall panel, then heat transfer inhibition is improved, but manufacturing complexity and installation cost increase

Engineering Contradiction:

Improveheat transferVSAvoidformation and installation complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

A foam board layer is introduced as an intermediary between the radiant barrier and the drywall panel. This foam board serves multiple functions: it provides structural support for the radiant barrier, creates an air gap for enhanced thermal insulation, and simplifies installation by being a pre-formed, manageable component. The radiant barrier is adhered to the foam board rather than directly to the drywall, reducing installation complexity while maintaining or improving thermal performance.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Loss of energy

If complex formation techniques are used for radiant barrier, then heat transfer inhibition is improved, but installation cost increases

Engineering Contradiction:

Improveheat transferVSAvoidinstallation cost

Core Design Contradiction:

Loss of energyVSEase of manufacture

Solution Approach 1:

The insulation system is segmented into distinct functional layers: the drywall panel, the foam board with integrated air gaps, and the radiant barrier. This segmentation allows each component to be manufactured and prepared separately with optimized simplicity, then assembled together. The foam board is produced as a standard building material with regular dimensions, avoiding complex custom formation processes and reducing overall installation cost.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system combines multiple materials with complementary properties: drywall for structural integrity and fire resistance, foam board for conduction and convection resistance, and radiant barrier for radiation reflection. This composite approach achieves superior overall thermal performance using simple, cost-effective individual components rather than requiring complex formation techniques for a single material.

Inventive Principle:

Principle #40Composite materials

3Loss of energy

If air gap is created between drywall and radiant barrier, then insulation against heat transfer is improved, but device complexity increases

Engineering Contradiction:

Improveheat transferVSAvoidpanel structure

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The air gap function is merged into the foam board structure itself. The foam board is attached to the drywall panel, and the radiant barrier is attached to the foam board, creating built-in air spaces as an inherent feature of the assembly rather than requiring separate air gap components. This integration simplifies the overall structure while maintaining the thermal benefits of air gaps.

Inventive Principle:

Principle #5Merging (Combining)

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

This configuration enhances insulation against heat transfer through conduction, convection, and radiation, maintaining cost competitiveness and ease of installation, thereby improving thermal performance without increasing construction time or complexity.

Implementation Method 1

a corrugated sheet interposed between the panel of drywall material and the radiant barrier, the corrugated sheet configured to provide an air gap between the panel of drywall material and the radiant barrier

Methodology Applied

Scientific EffectThermal Insulation: Thermal Insulation

Implementation Method 2

enhances insulation against heat transfer through conduction, convection, and radiation

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

a radiant barrier including a material reflective to heat

Methodology Applied

Scientific EffectThermal Radiation: Thermal Radiation

Implementation Method 4

radiant barrier including a material reflective to heat

Methodology Applied

Scientific EffectReflection: Reflection

Data Source

PatentUS11391045B2Insulating wall panels for building construction and related methods

Publication Date: 2022.07.19 R-ROK SOLUTIONS LLC

AI summary

Wall panels for building construction may include a corrugated sheet including a first series of peaks on a first side of the corrugated sheet configured for positioning to face a room interior. The corrugated sheet may also include a second series of peaks on a second, opposite side of the corrugated sheet configured for positioning to face a room exterior. A radiant barrier including a material reflective to heat may be secured only to the second series of peaks. The corrugated sheet may form pockets of air between the radiant barrier and the corrugated sheet.