Load-Bearing Thermal Break with Insulated Concrete Shell
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Solution Overview
Problem
In buildings with overhangs or extensions, heat transfer occurs due to the high thermal conductivity of structural elements penetrating the building envelope, necessitating a thermal break that isolates heat while maintaining structural integrity and strength.
Innovation Solution
A load-bearing thermal break constructed with concrete encasing insulating material and reinforcing bars, where the concrete is retained by a shell with shafts for rebar, providing shear strength and easy manufacturing, and featuring a symmetric hourglass design for effective heat isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If structural elements are used to support overhangs or extensions, then structural strength and stiffness are provided, but heat transfer occurs due to high thermal conductivity of the materials
Solution Approach 1:
The structural element is divided into multiple segments: an interior portion, an exterior portion, and an insulating material filling the cavity between them. This segmentation allows each portion to perform its specialized function while collectively providing both structural support and thermal isolation.
Solution Approach 2:
The thermal break assembly uses composite construction combining different materials with complementary properties: concrete or masonry for structural strength, insulating material for thermal resistance, and grout for bonding. This composite approach resolves the contradiction by integrating materials that excel at different functions.
2Loss of energy
If insulating material is added to break the thermal path, then heat transfer is minimized, but the structural strength and stiffness may be compromised
Solution Approach 1:
The insulating material is placed in the cavity between the interior and exterior structural portions, creating a thermal break without compromising the structural integrity of either portion. The segmentation allows the insulating material to perform its thermal function while the structural portions maintain load-bearing capacity.
Solution Approach 2:
The insulating material acts as an intermediary element between the interior and exterior structural portions. It mediates the thermal interaction by blocking heat flow while allowing the structural portions to remain connected and load-bearing through the grout and reinforcement.
3Loss of energy
If a thermal break is installed to meet building regulations, then thermal isolation is achieved, but the complexity of manufacturing and installation increases
Solution Approach 1:
The thermal break assembly merges multiple functions into a single integrated unit: the cavity form provides structural support, the insulating material provides thermal isolation, and the grout provides bonding and reinforcement. This merging simplifies manufacturing and installation compared to separate components.
Solution Approach 2:
The cavity form serves multiple functions: it provides the structural framework, defines the cavity for insulation, and acts as a mold for the insulating material and grout. This multi-functionality reduces the number of separate components needed, simplifying the overall system.
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 effectively minimizes heat transfer between interior and exterior while ensuring structural support and ease of manufacturing, meeting building regulations by using a concrete-insulation-rebar combination within a shell design that retains rebar and molds the concrete, enhancing building heating and cooling efficiency.
Implementation Method 1
The cavity is filled with insulating material to provide thermal isolation between the interior and exterior portions
Implementation Method 2
The cavity is filled with grout to bond the reinforcement to the interior and exterior portions
Data Source
AI summary
A load-bearing thermal break construction element for use in buildings, particularly with overhangs or extensions projecting from the exterior building envelope, comprises a concrete and insulation-filled shell with rebar extending therethrough. The shell has an interior space and a plurality of shafts extending through the interior space. The shafts are shaped to receive rebar in an interference fit, and may be shaped to permit the rebar to pivot while retained in place in the shell. The interior of the shell is filled with insulation and concrete prior to installation in a building.