Pourable EPS Thermal Insulation Layer
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Solution Overview
Problem
Existing methods for creating thermal insulation and leveling layers in building construction face challenges such as the need for multi-layer structures, difficulties in seamless installation, thermal bridging, and compatibility issues between material properties, particularly with the use of cut-to-size thermal insulation panels and pourable materials that require compaction to achieve compressive strength, which can compromise thermal insulation.
Innovation Solution
A pourable mixture comprising 24% expanded polystyrene (EPS) granules and a hydraulic setting process using a mineral binder mixture with white cement, silica, and non-activated kaolin, which improves conveyability and processing while maintaining thermal insulation and compressive strength properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If cut-to-size thermal insulation panels (EPS) are used, then thermal insulation properties are improved, but installation complexity and time increase due to inability to lay panels seamlessly
Solution Approach 1:
The patent combines thermal insulation panels with a pourable binding agent mixture to create a unified insulating layer. The binding agent fills gaps between panels and bonds them together, eliminating the need for separate installation steps and achieving seamless coverage while maintaining thermal insulation properties.
Solution Approach 2:
The invention creates a composite structure combining rigid EPS panels with a hydraulically setting pourable mixture. This composite approach allows the rigid panels to provide structural support and primary insulation, while the pourable mixture fills voids and creates continuous insulation, resolving the contradiction between panel-based insulation and seamless installation.
2Adaptability or versatility
If EPS panels are cut to fit around building services installations, then adaptability is improved, but thermal bridging increases creating harmful effects
Solution Approach 1:
The pourable binding agent acts as an intermediary material that fills the gaps and voids created when EPS panels are cut around building services installations. This intermediary substance creates a continuous thermal insulation layer around pipes and conduits, eliminating thermal bridges while maintaining adaptability to complex installation geometries.
3Quantity of substance
If natural insulating materials or mineral products are used, then cost is reduced, but insulation thickness must be increased due to high thermal conductivity
Solution Approach 1:
The patent creates a composite insulating layer combining EPS panels with a pourable mineral-based binding agent mixture. This composite structure allows the use of cost-effective mineral materials while maintaining compact thickness, as the bound EPS provides superior insulation properties that reduce the required overall thickness compared to using natural insulating materials alone.
4Strength
If aggregates are added to ensure compressive strength, then strength is improved, but thermal insulation properties deteriorate
Solution Approach 1:
The invention changes the binding mechanism from mechanical interlocking with aggregates to chemical bonding through hydraulic setting of a cementitious mixture. This parameter change allows the binding agent to achieve compressive strength through chemical hardening rather than aggregate interlocking, thereby maintaining thermal insulation properties while providing sufficient structural strength.
5Reliability
If multi-layer structures are used to meet building requirements, then functional performance is improved, but manufacturing complexity and work steps increase
Solution Approach 1:
The patent merges multiple functional layers into a single integrated system. The pourable binding agent mixture simultaneously provides leveling, bonding, and additional insulation functions that would traditionally require separate layers. This consolidation reduces manufacturing complexity while maintaining the functional performance of multi-layer structures.
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 solution enables a seamless, easily transportable thermal insulation and leveling layer with enhanced thermal insulation and compressive strength, minimizing thermal bridging and allowing for quicker walkability and coverage, while maintaining excellent sound-insulating properties.
Implementation Method 1
a pourable mixture for forming a thermal insulating and leveling layer, in particular for floor constructions, which pourable mixture hardens through a subsequent hydraulic setting process using a hydraulic binder
Data Source
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AI summary
The invention relates to a pourable mixture for forming a thermal insulation and leveling layer, particularly for floor constructions, which hardens through a subsequent hydraulic setting process. The mixture contains, among other things, expanded polystyrene (EPS) and a mineral binder containing non-activated kaolin. The pourable mixture is characterized above all by improved processing and conveying properties. Furthermore, the thermal insulation layer achieved after the setting process exhibits very good thermal insulation and compressive strength properties.