Hybrid Thermal Break Element with Metal and Non-Metallic Bars
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Solution Overview
Problem
Existing thermal break construction elements between building components, such as concrete floors and overhanging balconies, face challenges in minimizing heat loss and ensuring fire resistance, as steel reinforcement bars conduct heat and organic insulation materials compromise load-bearing capacity in fires, while non-metallic alternatives lack sufficient fire resistance.
Innovation Solution
A construction element featuring metal and thermally insulating non-metallic bars, where metal bars maintain connection integrity when non-metallic bars fail, and the arrangement of these bars, including stainless steel and basalt-based fibers, reduces heat conductivity and enhances fire resistance by distributing tensile forces effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel reinforcement bars are used to absorb tensile forces in thermal break elements, then the load-bearing capacity is improved, but heat loss increases due to high thermal conductivity
Solution Approach 1:
The reinforcement system is segmented into multiple materials: non-metallic bars (basalt, glass fiber, carbon fiber, or plastic) replace some steel bars to reduce thermal conductivity, while metal bars are retained in critical positions to maintain load-bearing capacity. This segmentation allows optimization of both thermal and mechanical performance.
Solution Approach 2:
The thermal break element uses composite construction combining organic insulation material (PIR, PUR, EPS, or XPS) with hybrid reinforcement bars (metal and non-metallic). This composite approach enables the structure to simultaneously achieve thermal insulation properties and mechanical strength requirements.
2Loss of energy
If non-metallic bars are used to reduce heat loss, then thermal insulation is improved, but fire resistance deteriorates
Solution Approach 1:
The bar system is segmented by material type and functional role: non-metallic bars handle normal tensile loading to reduce heat loss, while metal bars are positioned to provide fire safety backup. This segmentation ensures both thermal performance and fire resistance are achieved through specialized components.
Solution Approach 2:
Metal bars are installed as a pre-prepared safety backup that activates beforehand in case of fire. When non-metallic bars fail due to fire exposure, the metal bars immediately take over to maintain structural integrity, providing beforehand cushioning against fire-related structural failure.
3Loss of energy
If organic insulation materials are used for the insulating portion, then thermal insulation is improved, but fire resistance is reduced
Solution Approach 1:
The insulating portion uses organic materials (PIR, PUR, EPS, or XPS) combined with hybrid reinforcement bars. The organic insulation provides superior thermal performance, while the metal bars embedded within provide fire resistance, creating a composite system that compensates for the weaknesses of individual materials.
Solution Approach 2:
Metal bars are embedded within the organic insulation material during manufacturing, providing beforehand cushioning against fire-related structural failure. This integrated approach ensures that when the organic insulation is exposed to fire, the metal bars maintain structural integrity.
4Reliability
If thick layers of fire-resistant insulation material are used to improve fire resistance, then safety is improved, but cost and practicality deteriorate
Solution Approach 1:
The fire resistance function is extracted from the insulation material itself and transferred to the metal bars. This allows the use of thinner, more cost-effective organic insulation layers while maintaining fire safety through the metal reinforcement bars that remain structurally intact during fire exposure.
Solution Approach 2:
The solution changes the approach to achieving fire resistance by shifting from increasing insulation thickness to using material substitution in the reinforcement system. Metal bars with high fire resistance replace some non-metallic bars, achieving fire safety through material parameter changes rather than geometric changes.
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 minimizes heat loss by 30% and ensures structural integrity during fires, allowing for safe evacuation by maintaining a minimal connection strength, thus overcoming the limitations of traditional thermal break solutions.
Implementation Method 1
the bars comprise metal bars, as well as non-metallic bars formed of a thermally insulating material
Implementation Method 2
the metal bars are configured to maintain the connection when the tensile force absorbed by the non-metallic bars is lost
Implementation Method 3
The means for absorbing compression and shearing forces may consist of support blocks that are arranged below in the elongate portion
Data Source
AI summary
A construction element is for forming a connection between two parts of a building that are thermally insulated from one another. The element includes an elongate portion having a thermally insulating material, and configured to be placed between the parts of the building. Bars run through the thermally insulating portion and are configured to be anchored in the building parts that are to be connected and thus to absorb the tensile forces between the building parts. The element includes an insulating portion for absorbing compression and shear forces between the building parts. The bars include metal bars, as well as non-metallic bars formed of a thermally insulating material. The metal bars are configured to maintain the connection when the tensile force absorbed by the non-metallic bars is lost.