Precast Building Module Insulation Structure to Eliminate Thermal Bridges

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Solution Overview

Problem

Existing pre-cast modules for building construction lack effective insulation properties, leading to inefficient thermal isolation.

Innovation Solution

A modular building system with an insulating material layer containing grooves for steel rods embedded in concrete, ensuring complete thermal insulation by interlocking layers at junctions and incorporating recycled glass fibers for reinforcement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If segmented insulation bodies are used in grooves of pre-cast walls, then the insulation structure is simplified, but the insulation efficiency deteriorates

Engineering Contradiction:

Improveinsulation structureVSAvoidinsulation efficiency

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The insulation layer is segmented into multiple zones with different thicknesses (first thickness at edges, second thickness in central zones), allowing each segment to serve specific functions: edge segments provide structural support and perimeter insulation, while central thicker segments provide enhanced thermal isolation, eliminating the need for continuous complex insulation structures

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the insulation layer are assigned different thicknesses based on local insulation requirements. The central zones have greater thickness (second thickness) for maximum insulation, while edge regions have reduced thickness (first thickness) to accommodate structural constraints, optimizing overall insulation efficiency without uniform complexity

Inventive Principle:

Principle #3Local quality

2Reliability

If the insulating material layer is made thicker to improve insulation, then the insulation performance is improved, but the structural strength may be compromised

Engineering Contradiction:

Improveinsulation performanceVSAvoidstructural strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The module uses composite construction combining concrete structural elements with thermal insulation materials. The concrete layers (first and second concrete materials) provide structural strength, while the insulating material layers provide thermal isolation. This composite structure allows thick insulation zones without compromising overall structural integrity

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The insulation layer is divided into zones of different thicknesses rather than using uniform thickness throughout. Thicker insulation is applied only where needed for thermal performance, while thinner sections maintain structural efficiency, optimizing the strength-insulation balance

Inventive Principle:

Principle #1Segmentation

3Ease of manufacture

If grooves are arranged in a single-thickness layer, then the manufacturing is simplified, but the insulation performance is reduced

Engineering Contradiction:

Improvegroove arrangementVSAvoidinsulation performance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The insulation layer is segmented into multiple thickness zones with grooves strategically positioned in the thicker central zones. This segmentation allows grooves to be placed where they provide maximum insulation benefit without requiring complex multi-layer construction throughout the entire module

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Grooves are locally concentrated in specific zones of the insulation layer rather than distributed uniformly. This local concentration of grooves in thicker insulation zones maximizes insulation performance while keeping the overall manufacturing process simple and manageable

Inventive Principle:

Principle #3Local quality

4Adaptability or versatility

If on-site modifications such as drilling holes are made for wiring or pipes, then the adaptability is improved, but the insulation performance is degraded

Engineering Contradiction:

Improvewiring and pipe integrationVSAvoidinsulation performance

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

Wiring channels and pipe conduits are pre-integrated into the module structure during manufacturing, before the insulation layer is applied. This preliminary action allows utilities to be routed through dedicated pathways without requiring post-installation drilling or cutting that would compromise the insulation integrity

Inventive Principle:

Principle #10Preliminary action

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 provides enhanced thermal insulation without compromising structural strength, eliminating thermal bridges and reducing on-site modifications.

Implementation Method 1

the insulation material is a thermal insulator

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentEP4589089B1Building module

Publication Date: 2026.03.11 SHKUMBIN GASHI

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AI summary

A module for a modular building, the module comprising a base, a ceiling (4) and two sidewalls, the base, ceiling (4) and sidewalls delimiting an inner space (12), at least one of: the base, the ceiling (4) and the sidewalls having: a layer (20) of a first concrete material facing the inner space (12); a layer (22) of an insulating material arranged over the layer (20) of first concrete material; and a layer (36) of a second concrete material arranged over the layer (22) of insulating material.