Folded Sheet Metal Cladding Support for Sag and Thermal Loss
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Solution Overview
Problem
Existing cladding support systems face issues with sagging and inadequate support, particularly when securing horizontal beams, leading to thermal loss and increased material and time costs due to the need for multiple supports, which are often flimsy and inefficient.
Innovation Solution
A cladding installation support device made from folded sheet metal with a base, orthogonal top and side walls, and a clamp system that allows for adjustable placement and securement of cladding components, reducing thermal transfer and material usage while maintaining strength and adaptability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sheet steel supports are used to connect cladding components to building structures, then the supports can be simple and inexpensive, but they are flimsy and cause sagging and flexing especially when securing horizontal beams
Solution Approach 1:
The support device transitions from a two-dimensional flat sheet to a three-dimensional folded structure with vertical and horizontal walls forming a rigid framework. This dimensional transformation creates structural rigidity while maintaining material efficiency, solving the contradiction between simplicity and strength.
Solution Approach 2:
The support device combines sheet metal material with a folded geometric structure to create a composite system that achieves high strength-to-weight ratio. The folded configuration acts as a structural composite that provides both rigidity and adaptability.
2Strength
If more supports are added to prevent sagging and provide adequate support, then support strength is improved, but material and time costs increase
Solution Approach 1:
The support device is segmented into distinct functional walls (vertical wall for structural support, horizontal wall for cladding contact, rear wall for attachment) that work together to provide adequate support with a single unit, reducing the total quantity of supports needed.
Solution Approach 2:
The support device performs multiple functions simultaneously: it provides structural support, prevents sagging through its rigid folded geometry, enables thermal insulation through the air gap it creates, and facilitates easy installation through its adaptable design. This multi-functionality reduces the need for additional specialized supports.
3Strength
If supports extend from the building structure to the cladding to provide support, then structural support is achieved, but thermal loss paths are created from the building structure to the exterior
Solution Approach 1:
The horizontal wall portion of the support device acts as an intermediary element that creates a thermal break between the building structure and the cladding. By positioning this wall to contact the cladding while maintaining spacing from the building structure, it interrupts direct thermal conduction paths.
Solution Approach 2:
The design extracts the support function from direct contact between building structure and cladding. By using the folded support structure that attaches to the building structure at one point and contacts the cladding through its horizontal wall, it separates the thermal paths while maintaining structural support.
4Strength
If polymeric, fiberglass or cast metal supports are used instead of sheet steel, then strength and stiffness are improved, but the supports become more expensive, heavier, and more complicated
Solution Approach 1:
The invention changes the geometric parameters of the sheet metal support through folding to create a three-dimensional rigid structure. This parameter transformation (from flat to folded) achieves strength and stiffness comparable to polymeric or cast metal supports while maintaining the advantages of sheet metal construction.
Solution Approach 2:
The folded sheet metal structure creates a composite geometric form that combines the simplicity of sheet metal with the structural performance of more complex materials. The folded configuration acts as a structural composite that provides rigidity without requiring expensive or heavy materials.
Data Source
AI summary
A cladding support device comprises a folded sheet metal body. The folded sheet method body includes a base wall, a top wall portion protruding out relative to the base wall, a side wall protruding from the base wall and having an upper edge adjacent the top wall portion; and a clamp on the top wall portion, the clamp including a substantially planar body with side edges extending between a coupled end to which the clamp is coupled to the sheet metal body and an outboard end and the clamp being positioned on the top wall with one side edge extending along the upper edge of the side wall.