Cementitious Façade Panels With Embedded Frames for Airtight Mounting
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Solution Overview
Problem
Cementitious panels, such as concrete or polymer panels, face challenges in adhering to curtain wall frameworks due to poor adhesive surfaces, requiring mechanical fastening that compromises the airtight seal and adds weight to the building structure.
Innovation Solution
The cementitious panels are manufactured with a glazing frame embedded during production, which is secured to the framework using a structural spacer tape and sealant, allowing for adherence without mechanical fastening, thus maintaining the airtight seal and reducing structural weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical fastening is used to attach cementitious panels to the framework, then the panels can be securely supported, but the airtight seal is compromised and the building structure weight increases
Solution Approach 1:
A glazing frame is introduced as an intermediary component between the cementitious panel and the framework. The glazing frame provides mechanical attachment points while the panel's back surface maintains direct contact with the framework through adhesive bonding, preserving the airtight seal without requiring penetrating fasteners
Solution Approach 2:
The traditional mechanical fastening system is replaced with an adhesive bonding system. The panel's back surface is bonded to the framework using adhesive, eliminating the need for mechanical fasteners that would compromise the airtight seal
2Strength
If mechanical fastening hardware is used to support cementitious panels, then the panels can be securely attached, but the building structure weight increases
Solution Approach 1:
Mechanical fastening hardware is replaced with adhesive bonding. The panel's back surface is bonded directly to the framework using adhesive materials, eliminating the weight of steel grids, brackets, and other mechanical attachment hardware
Solution Approach 2:
The heavy mechanical fastening hardware is extracted from the system. Only the essential glazing frame remains for structural integration, while the panel is supported through adhesive bonding, significantly reducing the overall weight
3Shape
If traditional casting methods are used to manufacture cementitious panels, then the panels can be produced with desired shapes, but the perimeter edges are rough and porous making encapsulation or clamping infeasible
Solution Approach 1:
The panel is segmented into two distinct zones: the front surface maintains the desired architectural shape with decorative features, while the back surface is prepared with a smooth, precise perimeter edge zone suitable for adhesive bonding. This segmentation allows both aesthetic and functional requirements to be met
Solution Approach 2:
Different surface qualities are applied to different regions of the panel. The front surface has the rough, textured quality needed for aesthetic purposes, while the back perimeter edges have a smooth, precise quality needed for adhesive bonding and framework integration
4Object-affected harmful factors
If cementitious panels are manufactured with smooth precise perimeter edges for encapsulation or clamping, then the airtight seal can be maintained, but the panels cannot be formed using traditional casting methods
Solution Approach 1:
The manufacturing process is segmented to treat the front and back surfaces differently. The front surface is formed using traditional casting methods for aesthetic purposes, while the back perimeter edges are separately prepared with smooth finishes through molding or post-processing to enable adhesive bonding
Solution Approach 2:
The smooth perimeter edges are prepared in advance during the manufacturing process, before installation. This preliminary preparation of the bonding surfaces ensures that the panels can be easily attached to the framework with proper airtight sealing
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
This method enables efficient, cost-effective installation of cementitious panels that maintain the airtight seal and reduce the weight burden on the building structure, eliminating the need for exterior access and separate steel grids.
Implementation Method 1
a structural glazing sealant is applied into and fills the gaps/slots, wherein the structural glazing sealant and the structural spacer tape, together, adhere and secure the panels to the curtain wall framework
Implementation Method 2
the panels are mounted by positioning the panels within the framework with a compression gasket sandwiched between the framework and the perimeter edges of the panels
Data Source
AI summary
A building façade is secured to a building structure having a plurality of vertically stacked levels defined by horizontally arranged floors therebetween. The façade includes a framework which is mounted to one or more of the floors and one or more cementitious façade panels which are mounted to the framework. The cementitious façade panels include a cementitious planar member and a glazing frame secured to the cementitious planar member. The cementitious façade panels are mounted to the framework by adhering the glazing frame to the framework. The framework can be mounted to one or more of the floors before or after the cementitious façade panels are mounted thereto. Preferably, the glazing frame is adhered to the framework by structural spacer tape and/or structural sealant, and the glazing frame includes anchor studs embedded in the cementitious planar member.