Insulated Construction Member with Polymer Thermal Break

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Solution Overview

Problem

Existing construction members lack effective thermal insulation, leading to inefficient thermal management in building structures, particularly in wall studs, top plates, and bottom plates, where thermal breaks are not adequately addressed.

Innovation Solution

An insulated construction member comprising two wooden rails with parallel positioning and planar wooden connectors, filled with polymer insulation, which creates a thermal break and is reinforced by the connectors, reducing thermal transfer and maintaining structural integrity through hourglass-shaped connectors made from oriented strand board or plywood.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If polymer insulation is added to create a thermal break, then thermal insulation performance is improved, but structural strength and load-bearing capacity deteriorate

Engineering Contradiction:

Improvethermal transferVSAvoidstructural strength

Core Design Contradiction:

Loss of energyVSStrength

Solution Approach 1:

The construction member uses a composite structure combining wood (structural function) and polymer insulation (thermal insulation function). The wood components provide structural strength and load-bearing capacity, while the polymer insulation material provides thermal break functionality. This composite approach allows both thermal insulation and structural strength requirements to be satisfied simultaneously.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The construction member is divided into discrete components: separate wood sections (first and second wood components) connected by fasteners, with insulation material positioned in the gap between them. This segmentation allows the structural elements to remain distinct and load-bearing while the insulation material fills the thermal bridge path without compromising the structural integrity of the individual wood components.

Inventive Principle:

Principle #1Segmentation

2Loss of energy

If insulation material is positioned between wooden rails, then thermal break is improved, but device complexity increases

Engineering Contradiction:

Improvethermal transferVSAvoidconstruction member complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The wood components serve multiple functions: they provide structural support, maintain spacing between rails, and serve as attachment points for fasteners. The polymer insulation material simultaneously provides thermal insulation and fills the gap between wood components to maintain structural alignment. This multi-functionality reduces the need for additional dedicated components, thereby limiting complexity increase.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Strength

If wooden connectors are used to maintain spacing, then structural integrity is improved, but thermal insulation performance deteriorates

Engineering Contradiction:

Improvestructural integrityVSAvoidthermal transfer

Core Design Contradiction:

StrengthVSLoss of energy

Solution Approach 1:

The wood components are positioned only at the ends and critical connection points of the construction member, providing structural integrity where needed most. The polymer insulation material fills the remaining gap space between wood components, providing thermal insulation in the areas where structural support is not required. This localized placement of wood minimizes thermal bridging while maintaining necessary structural strength.

Inventive Principle:

Principle #3Local quality

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 provides enhanced thermal insulation, reduces weight, maintains structural spacing, distributes loads, and minimizes stress concentration, while ensuring secure retention of insulation and improved connection points for nailing, thereby improving thermal characteristics and structural performance.

Implementation Method 1

A polymer insulation is positioned between the first wooden rail and the second wooden rail completely filling the thermal break

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

The second wooden rail is positioned in parallel spaced relation to the first wooden rail. This parallel spaced relation creates a thermal break between the first wooden rail and the second wooden rail

Methodology Applied

Scientific EffectThermal break: Thermal Insulation

Data Source

PatentUS11591797B2Insulated construction member

Publication Date: 2023.02.28 FERGUSON BRANDON

AI summary

An insulated construction member has a first wooden rail and a second wooden rail. The second wooden rail is positioned in parallel spaced relation to the first wooden rail. This parallel spaced relation creates a thermal break between the first wooden rail and the second wooden rail. A series of planar wooden connectors are positioned at spaced intervals along the length of the first wooden rail and the length of the second wooden rail. Each of the planar wooden connectors extends across the thermal break between the first wooden rail and the second wooden rail. A polymer insulation is positioned between the first wooden rail and the second wooden rail completely filling the thermal break. The polymer insulation encapsulates the series of planar wooden connectors, with the polymer insulation being reinforced by the series of planar wooden connectors.