Fastener-Free Wall Assembly Using Structural Foam Adhesion

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Solution Overview

Problem

Conventional wall assemblies require fasteners for assembly and insulation, increasing manufacturing costs and time due to the need for coupling multiple components together.

Innovation Solution

A high performance wall assembly featuring a frame assembly with a structural foam layer that couples vertical members and a rigid foam insulating panel without fasteners, using a structural foam layer to adhere the panel to the frame and eliminate the need for fasteners, thereby reducing construction time and costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If fasteners are used to couple the frame assembly and insulating layer, then the structural integrity is ensured, but the manufacturing cost and manufacturing time increase

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing time

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent combines the fastening function and insulation function into a single integrated rigid foam insulating panel with attached fastening elements. The fastening elements are pre-attached to the insulating panel, merging two separate components (fasteners and insulation) into one unified component, thereby reducing assembly steps and manufacturing time while maintaining structural integrity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The fastening elements are pre-attached to the insulating panel during manufacturing, rather than being installed separately during construction. This preliminary action of pre-assembly reduces on-site construction time and simplifies the installation process, allowing the entire wall assembly to be constructed more quickly without compromising the coupling strength

Inventive Principle:

Principle #10Preliminary action

2Strength

If fasteners are used to assemble the wall assembly, then the components are securely coupled, but the manufacturing cost increases

Engineering Contradiction:

Improvecoupling strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent merges the fastening function and insulation function into a single integrated rigid foam insulating panel with attached fastening elements. The fastening elements are pre-attached to the insulating panel, merging two separate components (fasteners and insulation) into one unified component, thereby reducing assembly steps and manufacturing time while maintaining structural integrity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses a composite structure where the rigid foam insulating panel is combined with fastening elements to create an integrated assembly. This composite approach allows the insulation material and fastening components to work together as a unified system, reducing the need for separate fastening operations and associated costs

Inventive Principle:

Principle #40Composite materials

3Reliability

If multiple fasteners are used to couple frame members and insulating layer, then the assembly is secure, but the device complexity increases

Engineering Contradiction:

Improveassembly securityVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The rigid foam insulating panel serves multiple functions simultaneously: it provides thermal insulation, acts as a substrate for attaching exterior coverings, and includes integrated fastening elements for securing the panel to the frame assembly. This multi-functionality reduces the number of separate components needed in the wall assembly system

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 allows for faster and more cost-effective construction of wall assemblies by eliminating the need for fasteners, while maintaining structural integrity and thermal resistance through the use of a rigid foam insulating panel and structural foam layer.

Implementation Method 1

The structural foam layer couples the rigid foam insulating panel to the frame assembly. The structural foam layer also couples the plurality of vertical members to the top and bottom members

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS11131089B2High performace wall assembly

Publication Date: 2021.09.28 BASF SE

AI summary

A high performance wall assembly receives an exterior covering of a building. The high performance wall assembly includes a frame assembly having a top member, a bottom member opposite the top member, and a plurality of vertical members. The vertical members are coupled to and extend between the top and bottom members. The high performance wall assembly also includes a rigid foam insulating panel coupled to the frame assembly. A structural foam layer is disposed on the plurality of vertical members and on the rigid foam insulating panel. The structural foam layer couples the rigid foam insulating panel to the frame assembly and couples the plurality of vertical members to the top and bottom members such that the high performance wall is free of fasteners.