Polymeric Bracket Thermal Break for Building Insulation
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Solution Overview
Problem
Conventional metal wall and roof assemblies experience reduced warranties and life cycles due to thermal cycling and material reactions, such as oxidation, caused by metal-to-metal contact through fasteners and anchors, leading to thermal bridging and compromised insulation.
Innovation Solution
A polymer-based insulation system with bracket members and splice members that create a thermal break by using elongated ribs to deform and seal into insulation panels, preventing metal-to-metal contact and providing a vapor barrier, while using a polymeric material with high R-values to reduce thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal anchors and fasteners are used to attach cladding to building substrate, then structural support and attachment strength are improved, but thermal bridging increases and insulation efficiency deteriorates
Solution Approach 1:
The patent introduces polymeric bracket members as intermediary elements between metal anchors and cladding panels. These brackets are positioned to prevent direct metal-to-metal contact, creating a thermal break that interrupts heat flow paths while maintaining structural attachment functionality. The polymeric material serves as a mediator that provides both mechanical support and thermal insulation.
Solution Approach 2:
The system employs composite construction by combining metal anchors with polymeric bracket members. This composite approach allows the system to leverage the high strength of metal for anchoring while utilizing the low thermal conductivity of polymers to eliminate thermal bridging, achieving both structural integrity and thermal performance.
2Ease of manufacture
If metal components are in direct contact with building substrate and cladding, then installation simplicity is improved, but material reactions such as oxidation occur and durability deteriorates
Solution Approach 1:
Polymeric bracket members serve as protective intermediary layers between dissimilar metal components (anchors and cladding). This separation prevents direct galvanic contact that would cause oxidation and corrosion, thereby extending system lifespan while maintaining installation simplicity through the integrated bracket design.
Solution Approach 2:
The polymeric material creates an inert environment between metal components, preventing oxidation reactions by isolating dissimilar metals from direct contact with each other and from moisture pathways, thus eliminating the chemical conditions necessary for galvanic corrosion.
3Loss of energy
If additional sealing components (caulk, tape, spray membrane) are added to prevent thermal bridging, then insulation performance is improved, but system complexity and construction difficulty increase
Solution Approach 1:
The patent merges multiple functions into the polymeric bracket members, which simultaneously provide structural support, thermal breaking, and vapor barrier functionality. This consolidation eliminates the need for separate sealing components like caulk, tape, and spray membranes, reducing system complexity while maintaining or improving insulation performance.
Solution Approach 2:
The polymeric bracket members are designed as multi-functional elements that perform attachment, thermal insulation, and vapor barrier functions in a single component. This universal design simplifies the overall system by replacing multiple specialized components with one integrated solution that addresses all three requirements.
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 eliminates thermal bridging, enhances insulation efficiency, and extends the lifespan of building enclosures by maintaining a thermal break and preventing material reactions, thus improving the overall thermal performance and durability of building enclosures.
Implementation Method 1
the insertion of the respective upper rib and lower rib at least elastically deforms the longitudinal slot into which they are inserted so as to effectively seal along a length thereof
Implementation Method 2
using a polymeric material with high R-values to reduce thermal conductivity
Data Source
Figure 1
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Figure 5
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.