Structural Insulated Panel Joints With Pre-Installed Compressible Seals
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Solution Overview
Problem
Conventional structural insulated panels require time-consuming and skill-dependent field application of sealants at joints, which can be ineffective, and use wood frame members that do not provide optimal thermal insulation performance, leading to inefficiencies in thermal boundary maintenance and weight.
Innovation Solution
The structural insulated panel system features frame members with integrated recesses and projections that incorporate compressible seals, eliminating the need for field-applied sealants and enhancing thermal insulation by using a structural labyrinth seal and voids filled with insulation material, allowing for improved assembly and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If field-applied sealants are used at frame member joints, then joint sealing is achieved, but assembly time increases and effectiveness varies based on installer skill
Solution Approach 1:
Compressible seals are pre-installed into recesses of frame members during manufacturing, and projections are pre-formed on adjacent frame members. This preliminary preparation eliminates the need for field-applied sealants, as the sealing components are already in place and only require compression during assembly to become effective.
Solution Approach 2:
The compressible seals automatically seal the joint when the projections from adjacent panels compress them during assembly. The system self-seals without requiring external application of sealants by installers, making the sealing process automatic and consistent regardless of installer skill level.
2Ease of manufacture
If wood frame members are used, then cost is reduced and basic structural support is provided, but thermal insulation performance is insufficient
Solution Approach 1:
Voids are created within the frame members and filled with insulation material. This porous structure allows the frame members to provide thermal insulation while maintaining structural integrity, reducing heat loss through the frame members without requiring solid wood construction.
Solution Approach 2:
The frame members combine wood structural components with insulation material filled voids, creating a composite structure that provides both structural support and thermal insulation properties, addressing the limitation of plain wood frame members.
3Strength
If solid wood frame members are used, then structural strength is maintained, but weight increases
Solution Approach 1:
By creating voids within the frame members and filling them with insulation material, the overall density and weight of the frame members are reduced compared to solid wood construction, while the structural strength is maintained through the wood framework and compression of the compressible seals.
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 solution enables rapid, secure, and effective assembly of panels with enhanced thermal insulation and reduced weight, minimizing the need for field-applied sealants and improving thermal performance by utilizing compressible seals and strategically placed voids within the frame members.
Implementation Method 1
A first compressible seal is disposed within the recesses and configured to be compressed by the projections of an adjacent panel upon assembly of two panels to one another
Implementation Method 2
An insulation material is disposed within the cavity
Implementation Method 3
A plurality of voids are formed in at least one of the frame members and filled with the insulation fill material
Data Source
AI summary
An insulated enclosure includes a plurality of walls, each of the walls comprising structural insulated panels joined to adjoining structural insulated panels by joints. Each of the structural insulated panels includes a frame having a first vertical frame member, a second vertical frame member, a top frame member, a bottom frame member, and siding members disposed on opposing sides of the frame to define a cavity therebetween. The vertical frame members define, on an outwardly disposed surface thereof, a plurality of vertical recesses and projections. The joints between the plurality of structural insulated panels are butyl-free and include butyl-free compressible seals disposed between opposing recesses and projections in adjoining structural insulated panels. Insulation is disposed within the structural insulated panels and within at least a portion of at least one structural insulated panel vertical frame member.