Laminated Construction Element with Liquid Foam Insulation

Solution Overview

Problem

Existing construction elements, particularly roofing elements, face challenges in achieving a balance between thermal insulation, structural rigidity, walkability, and ease of forming recesses or bores, especially when using soft insulating materials like mineral wool, which require additional waterproofing and can be thick for identical thermal insulation compared to hard insulating materials like polyurethane.

Innovation Solution

A construction element comprising a laminated structure with a first layer of hard insulating foam applied in liquid form and hardened, providing structural rigidity and waterproofing, combined with a second layer of soft insulating material like mineral wool, allowing for adjustable properties such as flammability, impermeability, and sound insulation, and enabling better heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If soft insulating materials like mineral wool are used, then flame retardant and soundproofing properties are improved, but structural rigidity and walkability deteriorate

Engineering Contradiction:

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent combines soft insulating material (mineral wool or glass wool) with a rigid outer shell formed by waterproof membrane and framing members. This composite structure allows the soft material to provide flame retardant and soundproofing properties while the rigid shell provides structural rigidity and walkability support.

Inventive Principle:

Principle #40Composite materials

2Reliability

If soft insulating materials like mineral wool are used, then flame retardant properties are improved, but the ability to provide waterproof finish and structural rigidity deteriorates

Engineering Contradiction:

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The roofing element is divided into functional segments: soft insulating material for flame retardancy, waterproof membrane for water protection, and framing members for structural support. This segmentation allows each material to perform its specialized function without compromise.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A waterproof membrane is introduced as an intermediary layer between the soft insulating material and the external environment. This membrane provides the waterproof finish that soft materials cannot provide while allowing the soft material to maintain its flame retardant properties.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Loss of energy

If hard insulating materials like polyurethane are used, then thermal insulation efficiency is improved, but flammability and structural rigidity requirements become more difficult to balance

Engineering Contradiction:

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The patent uses composite materials combining soft insulating material with low flammability characteristics with a rigid protective shell. This allows achieving good thermal insulation while maintaining fire safety through the inherent fire-resistant properties of mineral or glass wool.

Inventive Principle:

Principle #40Composite materials

4Reliability

If identical thermal insulation is provided using soft insulating materials, then flame retardant properties are improved, but insulation thickness increases

Engineering Contradiction:

Core Design Contradiction:

ReliabilityVSLength of stationary object

Solution Approach 1:

The patent changes the density and composition parameters of the insulating material by using mineral wool or glass wool with optimized fiber structure. This allows achieving the required thermal insulation performance with controlled thickness while maintaining flame retardant properties.

Inventive Principle:

Principle #35Parameter 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 enhances the adaptability and performance of construction elements by providing optimal thermal insulation, structural stability, and ease of assembly, while minimizing transitions between insulating materials, thus offering a more efficient and practical solution for building elements.

Implementation Method 1

a first layer (8) which forms an external surface of the base plate or, at least, forms an insulating layer located closest to this external surface, said first layer being formed by an insulating foam which is applied in liquid form to the construction element in order to be hardened there

Methodology Applied

Scientific EffectFoaming: Foam

Implementation Method 2

an insulating foam which is applied in liquid form to the construction element in order to be hardened there

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 3

Building elements or building panels which can be used as roofing elements, as wall elements or as floor elements, these building elements comprising at least one base plate, said base being provided with ribs, an insulating material being disposed between said ribs

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentEP2110487B1Construction element and method of manufacturing construction elements

Publication Date: 2015.05.20

Figure 1~3
Figure 2

AI summary

Construction element, more especially for roof, wall or floor constructions, said construction element (1) comprising at least a base plate (2) which is provided with ribs (3) and an insulating material (4) being disposed between the aforementioned ribs (3), characterized in that the aforementioned insulating material (4) consists of at least a first layer (8) and a second layer (9) of different material, the aforementioned first layer (8) being made from an insulating foam.