Wall Assembly Thermal Bridging Reduction via Foam Encapsulation
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Solution Overview
Problem
Conventional structural steel wall framing assemblies experience thermal bridging, additional construction steps, and risks of air and water leakage due to the configuration of fasteners and insulation placement, which fail to meet energy codes and increase exposure to weather and condensation.
Innovation Solution
A structural lattice frame with vertical studs and horizontal furring separated by thermal isolation pads, where a continuous layer of closed-cell spray polyurethane foam insulation is applied inwardly to encapsulate the framing, reducing thermal bridging and integrating air and water-resistant barriers for efficient construction and compliance with energy codes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fasteners project inwardly through multiple layers to fasten into structural steel studs, then the sheathing panels are securely attached, but thermal bridging occurs at each fastener location
Solution Approach 1:
A non-metallic fastener or thermal break element is introduced between the sheathing and the steel stud to interrupt the thermal path. This intermediary component allows mechanical attachment while preventing direct thermal conduction through the fastener, thereby reducing thermal bridging at attachment points.
2Loss of energy
If continuous insulation is located outward of the sheathing, then energy codes are met, but the insulation is exposed to weather, condensation, and atmospheric dirt
Solution Approach 1:
The position of continuous insulation is inverted from the conventional exterior location to an interior location, placing it on the warm side of the sheathing assembly. This inversion protects the insulation from direct weather exposure, condensation, and atmospheric contaminants while maintaining its thermal performance and meeting energy code requirements.
3Ease of operation
If cladding systems penetrate the continuous thermal insulation, then cladding attachment is achieved, but thermal bridging occurs at penetration points
Solution Approach 1:
Thermal break elements or non-conductive fasteners are used at cladding penetration points to interrupt the thermal path. These intermediaries allow cladding to be securely attached while preventing thermal bridging through the penetration points, maintaining the continuity of the thermal envelope.
4Ease of operation
If zee or hat channel furring is added to receive cladding and continuous insulation, then cladding support is provided, but additional construction steps and air/water leakage risks are introduced
Solution Approach 1:
The functions of structural support, insulation support, and cladding attachment are merged into a single integrated sheathing assembly. The sheathing panels are directly attached to structural studs and provide the substrate for cladding attachment, eliminating the need for separate furring channels and reducing construction steps while maintaining structural integrity and reducing air/water leakage paths.
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 significantly reduces thermal bridging, minimizes exterior construction steps, and meets energy codes by encapsulating the structural framing with continuous insulation, providing a comprehensive air and water-resistant barrier while maintaining structural integrity and fire resistance.
Implementation Method 1
a continuous layer of closed-cell spray polyurethane foam insulation located entirely on the inward side of the sheathing to encapsulate and isolate the structural lattice frame from the exterior sheathing
Implementation Method 2
vertical studs and outwardly located horizontal furring having thermal isolation pads at the framing intersections
Data Source
AI summary
The present invention is directed to a wall assembly comprising a novel structural lattice frame comprising vertical studs and outwardly located horizontal furring spaced with thermal isolation pads therebetween at the framing intersections, foam insulation encapsulating the furring and at least a portion of the vertical studs, and an exterior air- and water-resistant barrier-protected sheathing fastened to the outward side of the horizontal furring.