Prefabricated Curtain Wall Insulation Retention via Friction Brackets
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Solution Overview
Problem
Current curtain wall insulation systems are labor-intensive and pose safety risks due to the need for multiple screws and sharp fasteners, which increase installation costs and can lead to leaks or damage during the installation process.
Innovation Solution
A method involving prefabricated curtain wall assemblies with a bracket and clip system that allows for the friction-fit or screw-attachment of brackets to mullions and transoms, using clips with tapered legs to secure insulation without the need for extensive fastening, and stiffeners to prevent deformation of insulation under compressive forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple screws and sharp fasteners are used to attach insulation, then the insulation is securely retained, but labor intensity and safety risks increase
Solution Approach 1:
The patent extracts the sharp pin/impaling spike from the traditional insulation hanger system, replacing it with a blunt-tipped leg that achieves secure retention through friction and mechanical interlocking rather than penetration. This eliminates the safety hazard while maintaining the insulation retention function.
Solution Approach 2:
The patent introduces an intermediary mechanism (the bracket with receiving slot and leg assembly) that mediates between the fastener and the insulation material. The receiving slot guides and constrains the leg, while the flange provides a bearing surface, creating a controlled installation process that eliminates the need for sharp impaling actions.
2Reliability
If multiple screws and fasteners are used at 8-12 inches O.C., then the insulation is securely attached, but installation costs increase
Solution Approach 1:
The insulation panel serves its own attachment function through the integrated leg-receiving slot-flange mechanism. The leg of the insulation panel directly engages with the bracket's receiving slot and bears against the flange, eliminating the need for separate screws or fasteners and reducing installation steps and material costs.
Solution Approach 2:
The patent merges the attachment function into the insulation panel itself and the bracket structure. The bracket integrates the receiving slot and flange that work together to attach the insulation, while the insulation panel includes the leg that performs the attachment action, combining multiple functions into unified components.
3Reliability
If screws are driven into mullions, then the brackets are securely attached, but potential leak points and structural damage are created
Solution Approach 1:
The patent replaces the screw-driven mechanical fastening system with a friction-based mechanical interlocking system. The leg inserted into the receiving slot and bearing against the flange creates a secure attachment through friction and geometric constraint rather than threaded engagement, eliminating pilot holes and potential leak paths.
Data Source
AI summary
Assembling a multi-story building using a prefabricating a curtain wall assembly (CWA) involves assembling a structural frame and preparing the frame to receive a thermal insulation panel in a spandrel area. A thermal insulation panel is then supported in the spandrel area using a flange plate of a plurality of brackets that are secured to the frame. The thermal insulation panel is engaged or secured using one or more clips which retain the panel to the frame. The process continues by attaching the CWA which has been prefabricated to a floor slab on the building to form a portion of the building curtain wall.