Thermal Break Washer Integrating Insulation Support and Heat Resistance
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Solution Overview
Problem
The construction of buildings is hindered by the need for multiple shipments and increased construction steps due to materials with many components, leading to higher costs, longer construction times, and a higher likelihood of errors and damage.
Innovation Solution
A thermal break washer with a sealing body and mounting projections that self-supports on building insulation, allowing for reduced parts and efficient assembly by securing insulation and drainage materials to the building wall without penetrating the wall, thereby reducing heat transfer and moisture ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If materials with multiple components are used to secure building insulation and siding materials, then the building construction can be completed with proper structural support and material retention, but the construction cost and time increase due to requiring multiple shipments and additional construction steps
Solution Approach 1:
The patent combines multiple functions into a single washer component. The washer integrates: (1) a body portion that secures insulation to the building structure, (2) support projections that extend through drainage fabric and lathe to provide structural support, and (3) a thermal break function that reduces heat transfer. This consolidation eliminates the need for separate fasteners, support elements, and thermal break components, thereby reducing the number of shipments and construction steps while maintaining all necessary structural and thermal performance.
Solution Approach 2:
The washer is designed as a multi-functional component that simultaneously performs multiple roles: it acts as a fastener to secure insulation, provides structural support through protrusions that extend through multiple layers of building materials, creates a thermal break to reduce heat transfer, and maintains drainage pathways. This universal design allows a single component to replace what would traditionally require multiple specialized parts, reducing construction complexity and time.
2Reliability
If multiple fasteners and support elements are used to secure building materials, then the building materials can be properly retained and supported, but the construction time and likelihood of errors increase due to additional construction steps
Solution Approach 1:
The washer merges the functions of multiple fasteners and support elements into a single integrated component. The body portion provides fastening capability, while the support projections extend through drainage fabric and lathe to provide continuous structural support. This consolidation reduces the number of installation steps from multiple separate fastening and support operations to a single installation action, thereby improving construction efficiency while maintaining reliable material retention.
Solution Approach 2:
The support projections are pre-formed as integral parts of the washer body, extending through the drainage fabric and lathe layers. This preliminary configuration ensures that structural support is automatically provided as the washer is installed, eliminating the need for separate support installation steps and reducing the likelihood of installation errors.
3Ease of manufacture
If traditional fastening methods are used without thermal break considerations, then the installation process is simpler, but heat transfer between the exterior and interior of the building increases
Solution Approach 1:
The washer integrates a thermal break function directly into the fastening component. The washer body, made from a material with lower thermal conductivity than metal fasteners, creates a thermal barrier that interrupts heat transfer pathways through the building envelope. This allows the installation to remain simple while simultaneously reducing energy loss through thermal conduction, eliminating the need for separate thermal break components.
4Adaptability or versatility
If multiple separate components are used for securing building materials, then each component can be optimized for its specific function, but the number of parts to assemble at the construction site increases
Solution Approach 1:
The patent consolidates multiple functionally optimized components into a single integrated washer. The body portion is optimized for fastening and thermal breaking, while the support projections are optimized for structural support through the drainage fabric and lathe. By merging these previously separate components into one piece, the patent maintains functional optimization while dramatically reducing the quantity of parts that need to be handled and assembled at the construction site.
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
This solution reduces the number of parts needed at construction sites, enhances construction efficiency, and provides thermal insulation and moisture protection by inhibiting heat transfer and moisture penetration between the exterior and interior of the building.
Implementation Method 1
The underside of the washer includes one or more mounting projections configured to penetrate the insulation to initially self-support the washer
Implementation Method 2
The thermal break washer in accordance with the present invention inhibits heat transfer between the exterior and interior of a building
Implementation Method 3
The thermal break washer in accordance with the present invention inhibits moisture from penetrating into the interior of a building
Implementation Method 4
The aperture is configured to receive a fastener to secure the washer against the surface of a building material, such as rigid insulation
Data Source
AI summary
A thermal break washer and building construction fastening system and method includes a thermal break washer having an outerside, an underside, and a fastener aperture extending there through, with the outerside defining a solid upper surface. A mounting projection extends from the underside and a support projection extends from the outerside, with the mounting projection configured to be pressed into an inner building material to retain the thermal break washer on the inner building material, with the thermal break washer configured to receive a first fastener for securing the inner building material. An outer building material is placed on the support projection, with a retention washer having a plurality of apertures placed over the thermal break washer. The retention washer is configured to receive a second fastener through one of its apertures to secure the retention washer to the thermal break washer with the outer building material disposed there between.