Thermal Insulating Façade Component with Binder-Filled Voids

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Solution Overview

Problem

Existing thermal insulating façade construction components with ceramic components and external insulating materials suffer from shrinkage leading to visible cracks, especially under intense solar radiation, which compromises the structural integrity and microclimate of buildings.

Innovation Solution

A thermal insulating façade construction component featuring a shaped element of insulating material with internal gypsum coating, horizontal and vertical pass-through holes, and gaps filled with binder material, providing enhanced mechanical strength, vapour permeability, and a shifted centre of gravity for improved structural support and reduced cracking.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If thermal insulating material with pass-through holes is used to create vapour permeable walls, then vapour permeability is improved, but shrinkage occurs leading to visible cracks on the façade

Engineering Contradiction:

Improvevapour permeabilityVSAvoidstructural integrity

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent combines thermal insulating material with gypsum binder material in a composite structure. The gypsum fills the pass-through holes and coats the internal vertical wall, creating a composite material that maintains vapour permeability while eliminating shrinkage cracks. The gypsum layer provides structural stability and prevents the cracking that occurs with pure thermal insulating materials.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The gypsum binder material is applied locally in specific areas: coating the internal vertical wall and filling the pass-through holes. This localized application provides crack prevention and structural reinforcement exactly where needed, while maintaining the overall vapour permeable structure of the thermal insulating material.

Inventive Principle:

Principle #3Local quality

2Temperature

If gypsum layers are added to thermal insulating elements to improve heat transfer performance, then thermal insulation is improved, but the centre of gravity shifts causing components to protrude outside the building frame

Engineering Contradiction:

Improveheat transfer performanceVSAvoidcentre of gravity position

Core Design Contradiction:

TemperatureVSShape

Solution Approach 1:

The gypsum layer is applied selectively only on the internal vertical wall facing the building interior, rather than uniformly on all surfaces. This localized application improves thermal insulation and shifts the centre of gravity inward toward the building interior, preventing protrusion outside the building frame while maintaining adequate heat transfer performance.

Inventive Principle:

Principle #3Local quality

3Strength

If external walls are filled with ceramic components and externally insulated, then structural strength is improved, but floor area is reduced due to component thickness

Engineering Contradiction:

Improvestructural strengthVSAvoidfloor area

Core Design Contradiction:

StrengthVSArea of stationary object

Solution Approach 1:

The patent uses a composite structure combining thermal insulating material with gypsum binder, creating a multi-functional element that provides both structural strength and thermal insulation in a single component. This eliminates the need for separate ceramic filling and external insulation layers, reducing overall wall thickness and maximizing floor area while maintaining structural integrity.

Inventive Principle:

Principle #40Composite materials

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 eliminates façade cracks, enhances mechanical strength and vapour permeability, and significantly improves thermal insulation and energy efficiency, reducing energy demand and CO2 emissions by doubling the heat capacity of thermal insulation compared to previous solutions.

Implementation Method 1

the heat capacity of gypsum contained in one square metre of thermal insulating construction elements amounting to 1731 kJ/W or 0.481 kWh/W, is twice as high as that in known solutions

Methodology Applied

Scientific EffectHeat capacity: Thermal Energy Storage

Implementation Method 2

the presence of a layer of binder material inside the construction component increases its rigidity, and additionally, the centre of gravity and accumulation potential of the construction component is even more favourably shifted towards the building interior than in solutions known so far

Methodology Applied

Scientific EffectVapour permeability: Permeation

Data Source

PatentEP3186456B1Thermal insulating faÇade construction component

Publication Date: 2018.09.26 ROLEK LEOPOLD

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AI summary

The thermal insulating façade construction component according to the invention comprises an element (1) made of thermal insulating material, wherein the internal vertical wall, located inside the building, is at least partially coated with a layer of binder material (4) bonded with the element. The element (1) has at least one horizontal hole (2), preferably two horizontal holes, and a vertical pass-through gap (3) oriented towards the upper and lower wall and a closed gap directed towards the side walls, whereby the pass-through holes (2) and the gap (3) are filled with binder material. The horizontal hole (2) intersects the vertical gap (3).