Insulated Concrete Wall System with Integrated Drywall
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing systems for forming insulated concrete walls face challenges such as unnecessary interior insulation inhibiting thermal mass effect, high labor costs due to extensive site work for removable formwork, requirement of additional drywall layers, lack of services cavity, and inflexibility in incorporating standard insulation panels or visual inspection of reinforcement bars.
Innovation Solution
A system comprising an outer insulation layer, an inner drywall layer spaced apart, and frame members interlocking both layers to maintain a cavity for concrete and services, allowing for tailored reinforcement placement and eliminating interior insulation to facilitate thermal energy transfer, with features like integral window and door sub-frames for improved assembly and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If insulating concrete forms are used with insulation panels on both sides, then the wall achieves insulation on both interior and exterior, but the interior insulation inhibits the thermal mass effect and thermal energy transfer
Solution Approach 1:
The patent removes the interior insulation layer from the wall assembly, extracting only the exterior insulation while maintaining the thermal mass concrete wall. This allows the concrete to directly contact the interior space and provide thermal mass effect without being inhibited by interior insulation materials.
Solution Approach 2:
The wall assembly is segmented into distinct functional layers: exterior insulation layer, concrete thermal mass wall, and interior finish layer. This segmentation allows each layer to perform its specific function optimally without interfering with thermal energy transfer from the concrete to the interior space.
2Loss of energy
If removable formwork systems are used, then the concrete wall can be formed with exterior insulation only, but extensive site labor is required for setup, stripping, removal, washing and storage
Solution Approach 1:
The formwork system is designed to be self-supporting and self-contained, with the insulation panels and formwork components integrated into a single assembly that remains in place during construction. This eliminates the need for separate setup, stripping, and storage operations required by traditional removable formwork systems.
Solution Approach 2:
The patent combines the insulation panels and formwork components into a single integrated assembly that serves multiple functions simultaneously: providing exterior insulation, supporting the concrete pour, and eliminating the need for separate formwork removal operations.
3Ease of operation
If additional drywall layers are attached to the inside of the thermal mass wall, then the interior finish is achieved, but the process becomes very labor intensive and expensive
Solution Approach 1:
The interior finish layer is pre-installed as part of the formwork assembly before the concrete pour, eliminating the need for subsequent drywall installation operations. This preliminary action integrates the interior finish into the construction process rather than adding it as a separate post-construction step.
4Ease of manufacture
If conventional formwork systems are used, then the concrete wall can be formed, but visual inspection and certification of reinforcement bars becomes difficult
Solution Approach 1:
The formwork assembly serves as an intermediary structure that provides open access and visualization pathways for reinforcement bars during the construction process. This intermediary design allows inspection and certification of reinforcement placement without requiring disassembly or complex inspection procedures.
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 system enhances energy efficiency by allowing direct thermal mass interaction with the interior, reduces labor and production costs, and enables easier reinforcement inspection and certification, while accommodating standard insulation panels and finishes, thus improving overall building comfort and energy savings.
Implementation Method 1
the thermal mass wall absorbs and stores thermal energy from sunlight entering through open windows during the day, and from other direct and indirect sources, and slowly releases the stored thermal energy at night
Implementation Method 2
thermal energy stored in the wall being slowly released outside the building at night through convection and through open windows
Implementation Method 3
the exterior insulation inhibits thermal energy outside the building from entering the building or accumulating in the thermal mass wall
Data Source
AI summary
Disclosed herein is an insulated thermal mass concrete wall (100) constructed using a system (10). The system (10) comprises an outer insulation layer (12) and an inner drywall layer (14) spaced apart from the outer insulation layer. Vertical frame members, formed from several frame member modules (16) that are connected one on top of another, extend between the outer insulation layer (12) and the inner drywall layer (14) to interlock the insulation and drywall layers and maintain a space there between for receiving uncured concrete (18), in which conduits (19) for services can be embedded.