Thermal Break Spacer for Curtain Wall Insulation
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Solution Overview
Problem
Curtain wall systems face challenges in thermal insulation and structural support, as conventional materials like aluminum and steel are thermally conductive and lack effective thermal breaks, leading to heat transfer between the exterior and interior of buildings.
Innovation Solution
Incorporating thermally insulating structural spacers made of materials like fiberglass composite, such as 'DURACAST', which provide structural support and act as thermal breaks, integrated into the curtain wall panel frame to secure inserts and maintain structural integrity while reducing heat flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional thermally conductive materials like aluminum and steel are used for structural support in curtain walls, then structural strength and load-bearing capacity are improved, but thermal insulation performance deteriorates due to heat transfer between exterior and interior
Solution Approach 1:
A thermally insulating grommet is introduced as an intermediary component between the aluminum mullion and the structural insert. This grommet mechanically connects the two components while providing thermal isolation, allowing the system to maintain both structural strength and thermal insulation performance simultaneously
Solution Approach 2:
The curtain wall assembly combines different materials with complementary properties: aluminum mullions for structural framework, thermally insulating grommets for thermal isolation, and structural inserts for load-bearing support. This composite approach allows each material to perform its optimal function without compromising the others
2Loss of energy
If thermally insulating materials are used to reduce heat transfer, then thermal insulation performance is improved, but structural support capability deteriorates due to lower strength compared to metal materials
Solution Approach 1:
The structural support function is segmented from the thermal insulation function. The structural insert handles load-bearing requirements while the thermally insulating grommet handles thermal isolation, allowing each component to be optimized for its specific function without compromise
Solution Approach 2:
The thermally insulating grommet acts as an intermediary that transfers mechanical loads from the aluminum mullion to the structural insert while maintaining thermal isolation. This mediator component enables the system to achieve both structural strength and thermal insulation
3Ease of manufacture
If aluminum mullions are used for structural support, then ease of manufacture and structural strength are improved, but thermal insulation performance deteriorates due to high thermal conductivity
Solution Approach 1:
The thermally insulating grommet serves as an intermediary component that can be easily integrated into the aluminum mullion system. It provides thermal isolation while maintaining the manufacturing advantages of aluminum extrusions and allowing for straightforward assembly of the multi-component 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 use of thermally insulating spacers effectively supports the weight of curtain wall inserts and provides a significant thermal break, enhancing energy efficiency by minimizing heat transfer between the exterior and interior of buildings while maintaining structural integrity.
Implementation Method 1
The structural space secures the first insert to the frame and supports the weight of the first insert. The structural space is formed of a thermally insulating material.
Data Source
AI summary
A curtain wall panel includes frame with a first frame member defining a channel, a cover configured to extend over the first frame member, a spacer formed of a thermally insulating material, the spacer including a first end, a body, and a second end, the first end being configured to be secured in the channel of the first frame member in a cammed interference fit by rotating a body of the spacer, and the second end being configured to form a cammed interference fit with the cover. An insert is supported from the first frame member by the spacer with the cover fit onto the spacer to capture and secure the insert relative to the frame.