FIELD OF INVENTION

The present invention relates to insulation applied to the interior of a building with a gap relative to external wall. The gap is defined as the space between the inner surface of a wall and the outer surface of an insulation panel. More particularly, this invention pertains to connection of the floor plate to the wall of the building and to connection between the walls of the building.

BACKGROUND OF THE INVENTION

[0001] Present design of residential buildings in moderate climates is the result of development based on two different concepts. One, predominant in Europe, relies on structural skeleton which is insulated on the exterior. The other, predominant in North America, is based on a structural frame with in-wall insulation. [0002] The structural skeleton building has the advantage of a sturdy, long lasting structure allowing solid installation of components such as doors, windows and utilities. Further advantage is excellent fire resistance, break-in resistance and wind resistance. However, it has disadvantages. Some problems result from the

construction practice particularly involving plumbing and electrical installations. During construction, walls are first built and later irrationally reworked for utility installations. In addition, major installations are layered on the floor top surface significantly decreasing the valuable height of the ceiling. Furthermore, the floor is finished with expensive secondary concrete layer not contributing to floor load capacity, as well as unfavorably reducing its stiffness. The result is that later adaptations of the building’s interior or exterior, inevitable over a lifespan of the building, are extremely difficult, energy consumptive, expensive and often impossible. Construction of a structural skeleton building typically uses large amounts of steel reinforced concrete and brick materials thus significantly elevating embodied carbon of the building. [0003] Further major disadvantages of the structural skeleton building result from applying thermal insulation to the exterior of the building. Because the huge thermal mass of the building cannot react in time with weather changes, the general heating approach is to keep the whole building at a constant temperature throughout the cold season. Similarly, there is no reasonable solution to cooling the interior of the building int the hot season because the available cooling power is smaller than the installed heating power. The cooling units blow cold air onto occupants of a room

simultaneously with the walls radiating residual heat at higher temperature.

Obviously, this heating/cooling approach is extremely energy consumptive. By some accounts, buildings consume 40% of world energy, 20% of this for heating, ventilating and air conditioning. A logical solution to the wasteful energy

consumption of the structural skeleton building is to reduce the thermal mass by applying thermal insulation to its interior rather than to its exterior. Oddly, the reluctance to consider this solution comes from the traditional belief of the engineering community that nothing can be done about interstitial condensation at the exterior walls. Unwisely, the current solutions to reduce exorbitant operating energy consumption of the present and the newly constructed buildings are to throw more money and more embedded carbon into exterior insulation.

[0004] Additional disadvantage of the exterior insulation is that it diminishes the options for architectural appearance of buildings and makes mounting of exterior hardware difficult and expensive.

[0005] In contrast to the structural skeleton building, a structural frame building has a considerably lower thermal mass. In cold season, such building can be brought to a desired internal temperature very quickly. Thus, the energy management of a structural frame building can be much more adaptive to weather changes and to the inhabitants’ behavior resulting in energy saving. In practice, this potential is typically not taken to its full advantage. One reason can be poor structural integrity of the building frame. Such construction is typically made from wet wood with imprecise connections between components. Integration of doors and windows is poorly engineered and executed. Interior doors are not sealed. In fact, fire regulations require doors to have a large gap at the bottom. Inevitably, there are considerable air leaks within and on the periphery of the structural frame buildings. [0006] One advantage of the structural frame building is that entire installation of plumbing and electrical wiring in walls as well as in floors is easy. This allows for easy later adaptations. The resulting floor is relatively thin, however has a distinct problem of having low natural frequency at around 4Hz. This is close to the natural frequency of human intestines causing unpleasant sensation during movement. The occupants feel more like walking on a boat deck than in the house.

[0007] Overall, the main disadvantage of structural frame buildings is lack of structural integrity. After a few years, a typical house shows visible distortions. The real estate value of such buildings diminishes rapidly. Lack of structural strength makes the house vulnerable to wind and has poor break-in resistance. All climate advantages of using wood materials which reduce embodied carbon of the building are lost due to short life cycle of the building.

[0008] Recently, a significant improvement in structural strength of wood buildings was achieved by using solid CLT (Cross Laminated Timber) plates rather than beam and stud frame of typical North American construction. Better strength, dimensional stability and rigidity are achieved. However, building from solid construction elements makes utility installations difficult. A disadvantage is also that the building propagates noise easily. CLT building also requires finish of the facade similarly to traditional buildings. Important advantages of CLT building comes from the fact that its C0 ₂ footprint is reduced, that the panels are prefabricated and that the building requires less foundation. However, CLT building uses a lot of wood and sustainability of forests may limit its popularity.

[0009] There have been some attempts to address the structural problem of in-wall insulation construction. They focus mainly on better quality of structural elements by prefabricating sections of the wall to better standards. This comes at the cost of making such utility installations more difficult. Another approach is described in US20160369502A1 where better structural components, such as composites made by pultrusion, are proposed.

[0010] Conceptually, there have been more attempts to improve structural skeleton buildings. One idea is to pour concrete walls by using ICF (Insulating Concrete Form) made from expanded polystyrene modular blocks. This provides insulation to the exterior as well as to the interior of a structural wall. Exterior insulation reduces temperature oscillations of the structural core thus reducing interstitial condensation. A number of inventions describe ICF technology. US5704180 and

US20140026504A1 use versatile connectors between the insulating layers allowing mounting of drywall on the interior and building facade on the exterior.

US0160340891 Al describes mounting of the floor to the concrete structure through insulation layers. One invention, US20170218642A1 describes ICF without ties forming a waffle grid concrete core. Common problem to ICF improvements, however, is that interior insulation is in contact with the concrete core with a substantial thermal mass reducing efficiency of such insulation. The disadvantage is also that more concrete material is used for wall construction than needed by the building structural requirement, elevating the embodied carbon. Additional disadvantage is that alterations to utility installations or building renovations are difficult.

[0011] Some of the solutions to reduce energy loss of the wall involve the opposite of ICF, i.e. by insulating the center of the structural wall such as SIP (Structural Insulation Panel). Typically, exterior and interior concrete panels sandwiching the insulation are produced using concrete precast technology such as produced by Keegan Precast Ltd. and Peikko Group. Inevitably, some of the structural strength is lost with such design of walls. A limitation is also that the interior panels produced by concrete casting of the sandwich plate have more thermal mass than needed to compensate for diurunal temperature variations.

[0012] Few of the construction solutions incorporate air space in the wall to improve thermal efficiency and to prevent interstitial condensation. One invention

FR2593211 Al proposes a complete separation of the structural portion of the exterior wall from the interior insulation with a gap (Fig. 10 of the patent). Insulation is fastened to the wall using discrete ties. Another invention CN101476356A describes similar solution applying smaller gap by mounting the insulation panel to the structural wall with adhesion at discrete places. The advantage of these two solutions is that the thermal mass of the wall affecting the internal temperature of the dwelling is at a minimum, limited primarily to the drywall. Another advantage of the solution described in FR2593211 Al is that gap can be used by HVAC for ventilation and energy transfer purposes. Still another advantage is that structural integrity of the wall can be fully utilized for incorporating windows, doors and other utilities, such as blinds or shutters, without concern for thermal bridging through the wall at the place of mounting. Further advantage of a building featuring structural wall without incorporating the insulation is that it is suitable for the cost effective precast concrete panel technology. Although the panels are C0 ₂ intensive when made from concrete they may be recycled indefinitely if the design and the dimensions were standardized.

[0013] However, the separation of the exterior wall from the interior insulation with a gap such as proposed in FR2593211 Al is limited to the walls only and the above advantages cannot be fully utilized. No suitable corresponding solution for the complete building, especially at the connection of the floor plate to the walls, is provided.

SUMMARY OF THE INVENTION

[0014] Accordingly, one object of the present invention is to provide fixing means for connecting a floor plate to the wall of a building at a distance relative to each other. Another objective is to provide insulation to the interior of a building with a gap between the inner surface of the wall and the outer surface of the insulation panel. [0015] Fixing of the floor, which is typically a plate, is accomplished by using brackets fastened to a building wall at one mounting end and to the floor plate at the other mounting end. The brackets are comprising a load bearing gusset joining the mounting ends and bridging the distance between the building wall and the floor plate. The cross section of the gusset is small assuring a minimum thermal bridge between the wall and the floor. The advantage of this arrangement is that peripheral insulation of the floor plate can be easily accomplished by installing the insulation panels in the space between the building wall and the floor plate. Furthermore, the insulation panels can be installed with a gap to the building wall. The same insulation panels can be mounted to the inner surface of an exterior building wall with the gap relative to the outer surface of the insulation panel, providing un uninterrupted space between the floors and at the floor plate. Alternatively, the gap can be interrupted at the floor plate, if required, still allowing thermal insulation between the floor plate outer edges and the building wall. One advantage of installing the insulation panels with the gap is that interstitial condensation on the inner surface of the exterior building wall is eliminated. Further advantage is that the thermal mass affecting the interior of the building is small. It comprises only the interior finish of the insulation panels, usually a drywall, the furniture and the floor plate. A smaller thermal mass makes the interior of the building responsive to the regulation of interior temperature thus reducing overall energy consumption of the building. Temperature of different areas in a building can be efficiently maintained at different levels especially when the interior dividing walls are also thermally insulated. Furthermore, temperature regulation of such building can be optimized by adjusting to intermittent human occupancy thus further reducing overall consumption of energy. Still further advantage of providing space between the exterior wall and the insulation panels is that air flow through the space can be utilized to capture passive heating and cooling energy of the exterior building wall and use it for further decreasing of overall energy consumption of the building. Additional advantage of separating exterior building wall from the insulation panels with a gap is that windows, doors, blinds and shutters need to be insulated and sealed only to the insulation panel and not to the exterior wall, simplifying the design of the hardware as well as its installation. Yet another advantage is that the gap between exterior walls and insulation panels can be used for utility installation. This allows better utilization of ceiling height, easier renovations and repairs as well as a simpler floor design.

[0016] According to preferred embodiment of the present invention, the installation of the brackets is accomplished by using screws fastening the mounting ends which are provided with mounting plates. First mounting end is provided with a first mounting plate which is fastened to the building wall and second mounting end is provided with a second mounting plate which is fastened to the floor plate. The building wall is provided with a permanently embedded fastening seat abutting the first mounting plate, and the floor plate is provided with a permanently embedded fastening seat abutting the second mounting plate. Alternatively, in another embodiment of the present invention, the floor plate is provided with a cavity and the corresponding mounting end of the bracket is provided with an anchor fitting said cavity. The advantage of both methods of fastening is that all walls and floor plates of the building are removable and that they can be re-used.

[0017] The same type of bracket, as used for the connection of the floor plate to the building wall, is used to connect building walls at an angle, usually normal to each other. The brackets are comprising a load bearing gusset joining the mounting ends of the bracket and bridging the distance between the building wall inner surface and the outer edges of an adjoining wall. By connecting all structural walls of a building with the brackets, a large building structure can thus be constructed employing the same concept of internal insulation with the gap. One advantage of using structural plates for construction of buildings, as compared to structural frame, is the resulting high strength of the building. Another advantage is that the building wall plates can be prefabricated and engineered for use of less material, thus reducing the embodied carbon of the building. [0018] In another aspect, the load bearing gusset of the bracket, connecting the structural wall plates with the floor plate, can be modified to provide an elastic joint between the plates. This is accomplished by designing cut-outs to the gusset of the bracket. Flexible joints between the building plates provide dynamic isolation of the plates, each plate generally having its own distinct natural vibration frequency. In case of vibration of the building as during earthquake, distribution of energy to plates with different natural frequency has the effect of absorbing the vibration energy. Thus the advantage is that flexible joints provide earthquake protection of the building. Another advantage is that flexible joints reduce stresses between the plates in case of unstable foundation of the building.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Preferred embodiments of the present invention are illustrated in the attached drawings in which: [0020] Figure 1 is a partially cut away side elevation view of a floor connected to an exterior building wall with a bracket and showing an installed insulation panel.

[0021] Figure 2 is a perspective view of the bracket of Figure 1.

[0022] Figure 3 is a perspective view of a variation of the bracket of Figure 2. [0023] Figure 4 is a partial cut away perspective view of a floor plate connected to an exterior building wall with a bracket comprising an alternative mounting end with an anchor fitted to a floor plate with a cavity.

[0024] Figure 5 is a partial perspective view of embodiments of Figure 1 showing spacer channels for mounting insulation panels and an example of utility installation in the gap.

[0025] Figure 6 is a partial perspective view of embodiments of Figure 1 showing wall studs for mounting insulation panels installed continuously between the floors and showing an example of utility installations.

[0026] Figure 7 is a partial perspective view of embodiments of Figure 1 showing wall studs for mounting insulation panels installed between the floors and showing an example of utility installation.

[0027] Figure 8 is a partial cut away perspective view of an interior building wall connected to an exterior building wall with a bracket.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0028] The floor plate 1 fixed to the exterior building wall 2 of a building is illustrated in Figure 1. Bracket 3 is connecting the floor to the wall at the distance 4, providing space for installation of insulation panel 5 to the outer edge 6 of the floor plate while maintaining the gap 7 between the wall 2 and the panel 5. The gap 7 is defined by the space between the inner surface 8 of the wall 2 and the outer surface 9 of the insulation panel 5. [0029] Figure 2 shows details of the bracket 3. The mounting ends od the brackets are provided with mounting plates, plate 10 for mounting to the wall mounting seat 11 and plate 12 for mounting to the mounting seat 13 of the floor plate 1. The mounting plates are joined with the load bearing gusset 14. In the preferred embodiment of this invention the mounting plates of the bracket are fastened using screws 15.

Alternatively, the mounting plates of the bracket can be also welded to the corresponding seats of the wall and the floor.

[0030] Figure 3 shows an improved version of the bracket for connecting the floor plate to the building wall. It features gusset 16 which has two cutouts 17 and 18. These cutouts create members 19, 20 and 21 of gusset 16. Members 19 and 20 are stressed in tension by the weight of the floor plate while curved member 21 is stressed in compression. The in-plane flexibility of the members of the gusset 16 is providing an elastic joint between construction plates and thus earthquake protection of the building. [0031] The alternative method to fasten the mounting end of the bracket to the floor plate is shown in Figure 4. The end of the bracket is provided with anchor pin 22. Correspondingly, the floor plate is provided with the cavity 23 loosely accepting pin 22. The cavity is preferably a cylinder 24 welded to a rebars 25 reinforcement of the floor plate. At the assembly, the clearance between the pin anchor and the cylinder is filled with resin or soft metal alloy material. Disassembly is accomplished by melting the filling material.

[0032] One method of installing the insulation panel 5 to the inner surface of the exterior wall is illustrated in Figure 5. Spacer channels 26 are fastened to the internal surface 8 of the wall 2. The channels have the same width as the gap 7. The insulation panels 5 is then fastened to the face 27 of the channels. The internal surface 28 of the insulation panels are preferably finished with a drywall 29 covering the insulation panel. The spacer channels are provided with larger cutouts 30 and smaller cutouts 31. These cutouts are used for utility installations in the gap space. Figure 5 shows example installation of a drain pipe 32 and an electrical conduit 33. The advantage of the method shown in Figure 5 is that insulation panel 5 can be assembled from smaller pieces into one continuous layer of insulation. [0033] Another method of installing the insulation panel to the inner surface of the exterior wall is illustrated in Figure 6. Studs 34 are mounted to the inner surface 8 of the wall 2 using spacers 35 fastened to the surface 8. The spacers 35 have the same length as the gap 7. Insulation panels 36 are fitted between the adjacent studs and secured in place by the dry wall 29. The wall studs are provided with the lip 38 on the back face 37 to seal and retain the insulation panels. Channels 39 are provided for placing the utility installations and are fastened to the back face 37 of the wall studs 34.

[0034] Still another method of installing the insulation panel to the inner surface of the exterior wall is illustrated in Figure 7. This method may be required to satisfy the fire regulation for a fire stop at the outer edge of the floor plate. Insulation plate 40, preferably made from mineral wool, is placed between the internal surface 8 of the wall and the edge 6 of the floor plate 2. The advantage of the two methods shown Figure 6 and 7 is that the traditional frame techniques are applied for installing the internal insulation.

[0035] The same principle as for connecting the floor plate to the exterior wall of the building can be applied to connect other walls within the building at an angle to each other. Figure 8 illustrates the bracket 41 used for connection of internal wall 45 normal to the external wall 2. The bracket is mounted at end 42 to the exterior wall 2 and at end 43 to outer edge 44 of the internal structural wall 45. Bracket 41 in Figure 8 is shown with cutout 46 to provide for earthquake protection similarly as the bracket 40 shown in Figure 3. The gusset 47 of the bracket 41 prevents a thermal bridge from wall 2 to the wall 45 and allows similar installation of the insulation panels as the bracket 3 used for mounting the floor plate.