Cage-Type Embedded Rail for Facade Panel Support
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Solution Overview
Problem
Conventional mortar-based facade systems are difficult to install and remove, especially in unfavorable weather conditions, and existing mortarless systems are prone to failure due to inadequate support from suspension rails during extreme weather.
Innovation Solution
A modular facade system featuring panels with a cage-like embedded suspension rail, including a first four-sided frame, cross bars, and a tab for connecting to a surface, providing enhanced support and ease of installation while maintaining aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional mortar-based facade systems are used, then strength and stability are improved, but installation difficulty and weather dependency worsen
Solution Approach 1:
The facade system is divided into separate modular panels and suspension rails rather than a monolithic mortar-based structure. Panels can be manufactured independently and assembled on-site, allowing installation in various weather conditions without requiring mortar curing time or favorable environmental conditions.
Solution Approach 2:
The suspension rail is extracted as a separate component from the panel and wall assembly. The rail is embedded into the panel during manufacturing, creating a integrated support structure that can be independently installed and adjusted, eliminating the need for complex mortar-based anchoring systems.
2Strength
If conventional mortar-based systems are used, then strength is improved, but installation flexibility and year-round installation capability worsen
Solution Approach 1:
The suspension rail system provides adjustable and reconfigurable installation capability. The rail can be positioned at different heights and angles, and panels can be adjusted along the rail, allowing the system to adapt to various installation conditions and weather requirements throughout the year.
Solution Approach 2:
The suspension rail is embedded into the panel during manufacturing before installation. This preliminary action ensures proper positioning and support are pre-established, allowing installers to simply attach the panel to the wall without complex on-site adjustments or weather-dependent mortar work.
3Ease of operation
If separate suspension rail and panel components are used, then ease of installation is improved, but reliability during extreme weather worsens
Solution Approach 1:
The suspension rail is merged with the panel by embedding it during manufacturing. This creates a unified structure where the rail becomes an integral part of the panel, eliminating the risk of separate components detaching during extreme weather while maintaining the modular installation advantages.
Solution Approach 2:
The panel-suspension rail assembly functions as a composite structure combining the panel material and the rail material into a unified system. This composite approach ensures that the rail and panel move together as one unit, improving reliability during extreme weather conditions.
4Ease of manufacture
If only a small portion of the panel is supported by the suspension rail, then ease of manufacture is improved, but structural stability and support worsen
Solution Approach 1:
The suspension rail is strategically positioned and embedded at specific locations within the panel where it provides maximum structural support. The rail is designed with varying depths and positions to optimize both manufacturing ease and the stability of the panel composition, ensuring critical support areas are reinforced.
Data Source
AI summary
Provided are stone-like or brick-like veneer systems for covering walls. Specifically provided in embodiments are facade panels comprising: (i) a molded brick-like or stone-like panel; and (ii) a suspension rail partially embedded in the panel comprising: a first four-sided frame with horizontally and vertically disposed sides; one or more cross bar joining two or more sides of the first frame; a plurality of posts extending perpendicularly from the first frame or cross bars; a second four-sided frame in communication with the plurality of posts; a tab in communication with the frame for connecting the suspension rail to a surface.