Wall Assembly With Integrated Foam And Fiberboard
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Solution Overview
Problem
Conventional wall assemblies for buildings face issues with thermal resistance, moisture penetration, and structural strength due to seams in preformed panels, lack of thermal breaks, and damage during handling and installation, which compromise energy efficiency and durability.
Innovation Solution
A wall assembly comprising a frame assembly, an outer fiberboard laminated with a non-perforated, non-woven polyolefin membrane, and a closed cell foam layer that couples the fiberboard to the frame, providing enhanced thermal and moisture resistance while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If preformed panels are used for insulation and exterior sheathing, then construction speed and labor efficiency are improved, but seams between panels create pathways for weather elements and reduce thermal resistance
Solution Approach 1:
The patent combines the insulation layer and exterior sheathing into a single integrated panel structure, eliminating the seams between separate insulation panels and sheathing panels that would otherwise create pathways for weather elements. This merged design maintains the construction speed benefits while resolving the weather resistance issue.
Solution Approach 2:
The patent uses composite panel structures that integrate multiple functions (insulation, sheathing, and weather barrier) into single units. These composite panels eliminate the need for separate layered assemblies with intervening seams, thereby maintaining productivity while improving reliability against weather penetration.
2Temperature
If exterior rigid foam layer is applied to the exterior of the sheathing layer, then thermal insulation is improved, but the foam layer becomes damaged during handling and installation
Solution Approach 1:
Instead of placing the fragile exterior rigid foam layer on the outside where it is vulnerable to damage during handling, the patent inverts the arrangement by placing the foam layer inside the wall assembly, protected by the sheathing and other structural elements. This protects the thermal insulation during installation while maintaining its insulating function.
Solution Approach 2:
The patent provides protective layers and structural elements that cushion and protect the foam insulation from damage before and during the installation process. The sheathing and framing act as protective barriers that prevent direct handling damage to the foam layer.
3Strength
If sheathing layer is directly connected to the frame assembly, then structural strength is improved, but thermal energy flows through the frame assembly without a thermal break
Solution Approach 1:
The patent introduces thermal breaks as intermediary elements between the sheathing layer and the frame assembly. These thermal breaks mediate the connection, allowing the sheathing to be structurally supported while preventing direct thermal conduction paths through the framing members, thereby reducing energy loss.
Solution Approach 2:
The patent applies thermal breaks at specific locations where thermal conduction is most problematic (through the frame assembly), while maintaining direct structural connections in other areas. This localized application of thermal breaks addresses energy loss without compromising overall structural strength.
4Loss of time
If conventional prefabricated wall assembly is used, then construction time is reduced, but weather elements penetrate through seams and cause damage to interior sheathing
Solution Approach 1:
The patent merges the weather barrier function into the integrated panel structure itself, eliminating the need for separate barrier layers and reducing the number of seams. This maintains the time efficiency of prefabricated assemblies while preventing weather element penetration that damages interior components.
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 enhances thermal resistance, moisture resistance, and structural capacity, reducing energy losses and damage from weather elements while maintaining lightweight construction and efficient assembly processes.
Implementation Method 1
a closed cell foam layer disposed on and between the plurality of vertical members and extending from the exterior side of the frame assembly
Implementation Method 2
The solution enhances thermal resistance, moisture resistance, and structural capacity
Implementation Method 3
an outer fiberboard laminated with a non-perforated, non-woven polyolefin permeable membrane
Data Source
AI summary
Described herein is a wall assembly for use in walls of energy efficient residential or commercial buildings which can provide improved thermal resistance, moisture resistance and structural capacity. The wall assembly includes a frame assembly, an outer fiberboard, and a closed cell foam layer. The fiberboard is laminated with a lamination such as a non-perforated, non-woven polyolefin permeable membrane. The closed cell foam layer couples the frame assembly and the outer fiberboard. Also described herein is a method of manufacturing the wall assembly.