Monolithic Polyurethane Insulation for Container Residential Blocks
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Solution Overview
Problem
Existing methods for upcycling sea containers into residential units face challenges with thermal bridges and condensation issues, which impair thermal insulation and create germ formation, while previous solutions like prefabricated insulation boards and embedded retaining elements reduce the insulating effect.
Innovation Solution
The use of monolithic thermal insulation that completely fills gaps and is bonded to the ceiling and walls, combined with a vapor barrier layer and elastic materials to reduce noise transmission, along with underfloor heating and a dry screed as a heat buffer, enhances mechanical stability and insulation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If prefabricated insulation panels are used, then installation is simplified, but thermal bridges occur at joints reducing insulation effectiveness
Solution Approach 1:
The patent merges multiple insulation panels into a single monolithic insulation layer that completely fills the cavity between inner and outer shells. This eliminates the joints and thermal bridges that occur with prefabricated panels, while still allowing for practical installation through sequential filling and bonding processes.
Solution Approach 2:
The insulation is applied in segments through a sequential process: first filling the cavity, then bonding the inner shell, and finally bonding the outer shell. This segmentation allows the monolithic insulation to be installed practically while maintaining its continuous, bridge-free structure.
2Strength
If metallic connections and joints are used in container construction, then structural stability is achieved, but thermal bridges are created that reduce insulation performance
Solution Approach 1:
The monolithic insulation acts as an intermediary material that replaces metallic connections and joints in the thermal path. While structural connections remain metallic for stability, the insulation continuously bonds to these connections, creating a thermal break that eliminates thermal bridges while maintaining structural integrity.
Solution Approach 2:
The patent creates a composite construction where monolithic insulation material bonds to both inner and outer shells, forming a unified thermal barrier. This composite structure integrates the structural benefits of metallic connections with the thermal insulation properties of the continuous insulation layer.
3Reliability
If the cavity is completely filled with thermal insulation and bonded to ceiling and walls, then thermal bridges are eliminated, but the complexity of the construction process increases
Solution Approach 1:
The construction process follows a preliminary action sequence: first the cavity is filled with insulation material, then the inner shell is bonded to this filled cavity, and finally the outer shell is bonded. This sequential approach simplifies the overall process by breaking down the complex task of creating a monolithic insulation system into manageable, ordered steps.
4Strength
If fastening elements are embedded in the thermal insulation, then mechanical attachment is enabled, but the insulating effect is locally reduced
Solution Approach 1:
The patent applies local quality by concentrating fastening elements at specific strategic locations rather than distributing them throughout the entire insulation layer. This minimizes the total area where insulation is compromised while still providing sufficient mechanical attachment points for structural components.
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 approach eliminates thermal bridges, reduces moisture absorption, improves soundproofing, and meets passive house energy standards while maintaining structural integrity and recyclability.
Implementation Method 1
the thermal insulation completely fills the cavity and is bonded to the ceiling and walls
Implementation Method 2
The elastic material reduces the transmission of structure-borne sound between the building envelope and the interior
Implementation Method 3
the vapor barrier significantly reduces the moisture absorption of the thermal insulation
Data Source
AI summary
A residential block is disclosed comprising residential storeys arranged one above the other, wherein at least one of the residential storeys comprises residential units (1) adjacent to each other having: an outer shell (2) consisting of a cuboid container with a bottom surface (6), a cover (7), up to two lateral walls (8) and up to two end walls (9, 10); a cuboid interior (3) with an edge length of at least 2 m in each case, an accessible floor (12) with footfall sound absorption (17), a ceiling (13) and up to four room walls (14, 15); an intermediate space (4) formed between the cover (7) and the walls (8), and also between the ceiling (13) and the room walls (14); and a monolithic thermal insulation (5) made of polyurethane hard foam in the intermediate space (4). A method for producing a thermal insulation (5) of this kind is also disclosed.