Non-woven Thermoplastic Board for Foundation Wall Insulation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current insulation methods for foundation walls are costly, labor-intensive, aesthetically unpleasing, and lack durability, with existing materials like fiberglass boards and dimpled plastic sheets being hazardous, sensitive to UV light, and ineffective in withstanding hydrostatic pressures.

Innovation Solution

A non-woven thermoplastic insulation board with a rigid structure, enhanced thermal resistance, and a UV-protected outer skin layer, which can be bent without damage and is environmentally friendly, providing improved thermal insulation and hydrostatic resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If fiberglass boards are used for insulation, then thermal resistance is provided, but the material is hazardous to install and degrades with UV exposure

Engineering Contradiction:

Improvedurability of insulation materialVSAvoidUV sensitivity and installer hazard

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent employs a composite material system consisting of rigid foam insulation boards integrated with a protective coating layer. This composite structure combines the thermal insulation properties of foam material with the UV resistance and aesthetic qualities of the coating, resolving the contradiction between providing thermal resistance and resisting UV degradation.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent replaces traditional fiberglass boards with rigid foam boards that do not require immediate backfilling. This allows the insulation material to remain exposed to UV light temporarily during construction without degrading, effectively treating the material as durable enough for extended exposure rather than requiring immediate protection.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If fiberglass boards are installed on the exterior foundation wall, then insulation is provided, but detailed labor is required to achieve aesthetic appearance

Engineering Contradiction:

Improveinsulation performanceVSAvoidinstallation complexity and labor cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the insulation function and the aesthetic finish function into a single integrated system. The rigid foam boards are factory-prepared with integrated finishing surfaces, eliminating the need for separate aesthetic treatment steps and reducing on-site labor complexity while maintaining insulation performance.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent applies preliminary action by pre-preparing the insulation boards with factory-applied coatings or finishes before installation. This preliminary aesthetic treatment is performed under controlled manufacturing conditions rather than requiring detailed on-site work, reducing installation complexity and labor requirements.

Inventive Principle:

Principle #10Preliminary action

3Force

If dimpled plastic sheets are used, then hydrostatic pressure relief is provided, but thermal resistance is not achieved

Engineering Contradiction:

Improvehydrostatic pressure resistanceVSAvoidthermal insulation capability

Core Design Contradiction:

ForceVSTemperature

Solution Approach 1:

The patent uses a composite material - rigid foam insulation board - that inherently provides both thermal resistance and structural strength to resist hydrostatic pressure. This single material simultaneously addresses both requirements without needing separate dimpled plastic sheets, eliminating the contradiction between pressure resistance and thermal insulation.

Inventive Principle:

Principle #40Composite materials

4Loss of energy

If full wall exterior insulation is implemented, then energy efficiency is improved, but material cost and installation cost increase

Engineering Contradiction:

Improveheat exchange controlVSAvoidmaterial quantity and cost

Core Design Contradiction:

Loss of energyVSQuantity of substance

Solution Approach 1:

The patent changes the physical parameters of the insulation material by using rigid foam boards with optimized thickness and density. These parameter changes provide the required R-value with thinner, more cost-effective material compared to traditional fiberglass, reducing both material quantity and installation cost while maintaining energy efficiency.

Inventive Principle:

Principle #35Parameter changes

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 offers a cost-effective, durable, and aesthetically appealing insulation solution that effectively controls heat exchange and withstands hydrostatic pressures, reducing energy consumption and environmental impact.

Implementation Method 1

Insulation for a building's foundation wall can control the heat exchange between the ground and the interior of the foundation wall, thus saving energy

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

Insulation can also provide a hydrostatic pressure barrier between the surrounding earth and the foundation wall, thus providing structural advantages

Methodology Applied

Scientific EffectHydrostatic pressure resistance:

Data Source

PatentUS20230053240A1Material and method for providing insulation to a foundation wall

Publication Date: 2023.02.16 GARLAND IND INC

AI summary

A material and method for insulating a top portion of a foundation wall which includes a non-woven thermoplastic board for insulating a foundation wall. The non-woven thermoplastic board has a thermal resistance of an R-value per inch thickness of at least 1.