Cladding Elements via Flexible Support and Cement Impregnation
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Solution Overview
Problem
Existing methods for manufacturing cladding elements with complex shapes in construction are limited by the need for expensive and difficult-to-manufacture formworks, and they struggle to produce elements with variable translucent and/or transparent properties.
Innovation Solution
A method involving an elastically deformable support element with spacer elements forming interconnected cavities, into which a fluid cementitious composition is introduced and then partially removed to control distribution, allowing for the creation of complex shapes and variable translucency/opacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional formworks are used to manufacture cladding elements with complex shapes, then the desired shape can be achieved, but the manufacturing cost and complexity increase significantly
Solution Approach 1:
The patent uses a flexible support structure that can be deformed to copy complex shapes, replacing traditional rigid formworks. The support structure is impregnated with cement-based material to create cladding elements with desired complex geometries without requiring complex formwork systems
Solution Approach 2:
The patent changes the physical state and properties of the support structure from rigid to flexible, allowing it to be deformed into complex shapes. The flexible support can be stretched, bent, and molded to achieve various geometries before cement impregnation, eliminating the need for complex formworks
2Shape
If traditional formworks are used to manufacture cladding elements with complex shapes, then the desired shape can be achieved, but the production cost increases
Solution Approach 1:
The patent employs a flexible support structure that can be reused multiple times for manufacturing different cladding elements. The support is inexpensive compared to traditional formworks and can be deformed and repositioned for various shapes, reducing manufacturing costs for complex geometries
3Strength
If fabric with powder material is used to manufacture cladding elements, then structural elements can be obtained, but complex geometries cannot be realized
Solution Approach 1:
The patent uses a dynamic flexible support structure that can be deformed into various complex shapes before cement impregnation. The support maintains its structural integrity and can be molded into single or double curved geometries, folds, and other complex forms while providing mechanical resistance
4Strength
If fabric with powder material is used to manufacture cladding elements, then structural elements can be obtained, but translucent and transparent characteristics are lost
Solution Approach 1:
The patent applies local quality by selectively distributing cement-based material within the flexible support structure. By controlling the impregnation process, translucent and transparent zones can be created in specific areas while maintaining mechanical strength in other regions, achieving both properties simultaneously
5Strength
If uniform distribution of powder material in fabric is required, then mechanical resistance is maintained, but manufacturing complexity and cost increase
Solution Approach 1:
The patent employs a self-service mechanism where the flexible support structure itself facilitates uniform material distribution during impregnation. The fabric's structure and deformation state automatically ensure even distribution of cement-based material without requiring additional complex manufacturing processes or equipment
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
Enables the efficient and cost-effective manufacturing of cladding elements with complex shapes and variable light transmission properties, reducing material usage and production costs while maintaining mechanical integrity.
Implementation Method 1
maintaining such composite structure in association with the forming device, until solidification thereof
Data Source
AI summary
A method for manufacturing cladding elements for use in construction, including a composite cement-based structure, including an elastically deformable support element having a first surface, a second surface and a plurality of spacer elements having an elongated shape positioned between the first and second surface to realize a plurality of interconnected cavities. The method further provides preparing a substantially fluid and water-based cementitious composition and introducing the substantially fluid cementitious composition into the support element to obtain a composite structure in a deformable state. After this, part of the fluid cementitious composition is removed from the support element, to eliminate the excess fluid cementitious composition and position the deformable composite structure in a forming device. The method provides for maintaining the deformable composite structure in association with the forming device, until the consolidation thereof and that said support element is constituted by a three-dimensional elastically deformable fabric.