Polymer Bracket Insulation System Thermal Break
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Solution Overview
Problem
Conventional metal wall and roof assemblies experience reduced lifespan due to thermal cycling and material reactions, leading to thermal bridging and corrosion, and require additional insulation measures that are often improperly applied, compromising their insulative properties.
Innovation Solution
A polymer-based insulation system comprising bracket members with elongated bodies and ribs that deform into longitudinal slots of insulation panels, creating a vapor barrier and thermal break, and splice members that seal between panels, eliminating metal-to-metal contact and using a sealant or adhesive within slots for enhanced sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If metal skins are bonded to insulated panel cores to create foam panels, then thermal efficiency is improved, but the system becomes subject to thermal cycling damage and material reactions that reduce lifespan
Solution Approach 1:
The patent introduces non-metallic intermediaries (polymer brackets, foam insulation layers, and sealing materials) between metal cladding elements to break thermal conduction paths. These intermediary components prevent direct metal-to-metal contact while maintaining the structural integrity and thermal efficiency of the building envelope.
Solution Approach 2:
The patent changes the material parameters of the bracket system from metallic to non-metallic compositions, fundamentally altering the thermal conductivity properties. This material parameter change eliminates thermal bridging while maintaining mechanical support functions, thereby improving both thermal efficiency and system reliability.
2Strength
If metal to metal contact is used for structural support, then structural integrity is maintained, but thermal conductivity increases allowing heat to invade the building
Solution Approach 1:
The patent segments the structural support system into multiple non-metallic components (polymer brackets, foam core, sealing layers) that distribute structural loads while preventing continuous thermal conduction paths. This segmentation maintains structural integrity through distributed mechanical support while blocking heat transfer.
Solution Approach 2:
Non-metallic intermediary materials are inserted between metal cladding elements to serve as thermal breaks. These intermediaries maintain the necessary structural spacing and support functions while creating thermal resistance that prevents heat from traveling through the building envelope.
3Temperature
If additional insulation measures such as caulk, tape, and spray membrane are applied, then insulative properties are improved, but these components are difficult to control and properly apply during construction
Solution Approach 1:
The patent merges multiple insulation and sealing functions into an integrated bracket system that includes built-in foam insulation layers and sealing components. This consolidation eliminates the need for separate application of caulk, tape, and spray membrane, thereby improving insulative properties while significantly easing installation control and execution.
Solution Approach 2:
The bracket system incorporates pre-applied foam insulation and sealing components during manufacturing, so that insulation measures are already in place before installation at the building site. This preliminary action eliminates the complexity of coordinating multiple separate insulation applications during construction.
4Strength
If dissimilar materials are contacted to provide structural support, then structural requirements are met, but oxidation reactions occur causing corrosion over time
Solution Approach 1:
The patent changes the material composition parameter of the bracket system from metallic to non-metallic (polymer) materials. This fundamental material parameter change eliminates galvanic corrosion by removing the dissimilar metal contact that would otherwise occur between different metal components, thereby maintaining structural support while preventing corrosion.
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 system effectively reduces thermal conductivity, prevents corrosion, and maintains insulative properties by creating a continuous vapor barrier and thermal break, enhancing the durability and efficiency of building enclosures.
Implementation Method 1
The upper rib and the lower rib are structurally configured to extend into the longitudinal slot of the insulation panel. It will be understood that the insertion of the upper rib and the lower rib at least elastically deforms the longitudinal slot into which inserted so as to effectively seal along a length thereof.
Implementation Method 2
one of a sealant or an adhesive is disposed within the longitudinal slot corresponding to a junction of a splice and one of an upper rib and a lower rib
Data Source
AI summary
An insulation system for coupling to a building substrate comprising a plurality of insulation panels, bracket members and splice members. Each insulation panel includes a longitudinal slot. Each bracket member is formed from a polymer and includes an elongated body having a body wall, a first end wall and a second end wall. Upper and lower ribs extend from the body wall and are structurally configured to extend into the longitudinal slot of each of the plurality of insulation panels, and to elastically deform the longitudinal slot so as to effectively seal along a length thereof, defining a vapor barrier. A similar structure is on each splice member. The bracket members are positioned in a spaced apart relationship with insulation panels therebetween. The upper and lower ribs extend into corresponding ones of the longitudinal slots of the insulation panels, with splice members extending between adjacent adjacently abutting insulation panels.