Fire-Resistant Thermal Break Element for Building Connections
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Solution Overview
Problem
Existing thermal break construction elements for connecting building components, such as concrete floors and cantilevered balconies, face a trade-off between high thermal insulation and fire safety, as materials with better thermal insulation properties like PIR, PUR, and XPS have lower fire resistance compared to mineral wool variants.
Innovation Solution
A construction element featuring an elongate thermally insulating portion with a fire-resistant profile and a thermally insulating layer, where the underside and raised side walls are formed by a fire-resistant profile, and a thermally insulating layer is provided on the base surface, allowing for the use of high-quality insulating materials like PIR, PUR, and XPS while enhancing fire safety through a composite material and compressed rock wool layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If synthetic insulating materials like PIR, PUR, or XPS are used in thermal break elements, then thermal insulation properties are improved, but fire resistance deteriorates
Solution Approach 1:
The thermal break element is divided into multiple functional zones: a fire-resistant base profile (minimum 50mm height) made of non-combustible material, and synthetic insulating material (PIR/PUR/XPS) placed above this base. This segmentation allows the lower portion to provide fire protection while the upper portion maximizes thermal insulation, resolving the contradiction between fire safety and energy efficiency.
Solution Approach 2:
The element combines different materials with complementary properties: a fire-resistant base material (non-combustible profile) combined with synthetic insulating material (PIR, PUR, or XPS) that has superior thermal insulation properties. This composite structure allows the element to simultaneously achieve both fire resistance and high thermal insulation performance.
2Reliability
If mineral wool is used as insulating material, then fire resistance is improved, but thermal insulation properties deteriorate
Solution Approach 1:
The element is segmented vertically into two functional zones: the lower fire-resistant base (minimum 50mm) made of non-combustible material handles fire safety, while the upper zone uses synthetic insulating material for superior thermal insulation. This eliminates the need to rely on mineral wool for fire resistance, allowing use of more efficient synthetic insulators.
Solution Approach 2:
The composite structure combines a fire-resistant base material with synthetic insulating material, creating an element that achieves both fire safety and high thermal insulation performance without being limited to mineral wool, thereby improving overall thermal efficiency.
3Reliability
If the fire-resistant profile height is increased, then fire resistance is improved, but the density of insulating material required increases
Solution Approach 1:
The profile height parameter is optimized to a minimum of 50mm, which is sufficient to provide the required fire resistance. Above this height, synthetic insulating material is used to provide additional thermal insulation without requiring increased density, thus optimizing both fire safety and material efficiency.
Solution Approach 2:
The composite structure allows the fire-resistant base to be kept to the minimum necessary height (50mm) while achieving required fire resistance, and the remaining height is filled with low-density synthetic insulating material that provides superior thermal insulation without increasing overall density.
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 effectively maintains high thermal insulation properties while ensuring fire safety, as demonstrated by comparative fire resistance tests that show the constructed elements meet or exceed the fire resistance standards of those using mineral wool, allowing for the use of less dense, high-performance insulation materials without compromising fire safety.
Implementation Method 1
a thermally insulating layer is provided on the base surface of the profile (i.e., between the raised side walls)
Implementation Method 2
the underside and part of the raised side walls of the elongate portion is formed by a fire-resistant profile
Data Source
Figure 1a~1b
Figure 2~3
Figure 4~5
AI summary
The invention is related to a construction element for forming a connection between two parts of a building which are thermally insulated from one another. The element comprises an elongate portion (11) comprising a thermally insulating material (2), tension bars (5) which run through the thermally insulating portion (11) and which are configured to be anchored in the building parts that are to be connected, and components (7,8,9) for absorbing compression and shear forces between the building parts. The construction element according to the invention is characterised in that the underside and part of the raised side walls of the elongate portion (11) are formed by a fire-resistant profile (15) with a base surface (16) and two raised side walls (17), and wherein a thermally insulating layer (18) is provided on the base surface (16) of the profile.