Dry-Cast Veneer Blocks with Volumetric Pigmentation and Steel Molds
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Solution Overview
Problem
Wet-cast lightweight veneer products face issues with surface pigmentation leading to unsightly appearance when damaged, inability to be acid washed, and variability in shape due to flexible molds, along with a complex and time-consuming installation process requiring skilled labor.
Innovation Solution
The development of dry-cast lightweight veneer blocks with pigmentation mixed throughout the material, formed in steel molds for precise dimensions, and an installation system using an air barrier and adhesive for faster, simpler installation without mortar joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If wet-cast lightweight veneer products use surface pigmentation, then the product achieves desired aesthetic appearance, but the appearance becomes unsightly when chips or damage occur exposing unpigmented inner portions
Solution Approach 1:
The patent applies local quality by incorporating pigmentation throughout the entire volume of the concrete mixture rather than only on the surface. This ensures that any portion of the veneer, whether exposed or internal, maintains consistent color and aesthetic appearance even when damaged or cut.
Solution Approach 2:
The patent transitions from two-dimensional surface pigmentation to three-dimensional volumetric pigmentation by mixing pigment throughout the entire concrete mixture. This dimensional change ensures uniform color distribution throughout the bulk material, eliminating the appearance issues caused by chipping or damage.
2Ease of manufacture
If wet-cast lightweight veneer products use surface pigmentation, then the product achieves desired color, but the product cannot be acid washed without removing surface pigmentation and exposing unpigmented portions
Solution Approach 1:
The patent applies preliminary action by incorporating pigmentation into the concrete mixture before casting. This pre-mixing ensures that the color is embedded within the material itself, allowing subsequent surface treatments like acid washing to be performed without compromising the underlying color integrity.
3Ease of manufacture
If wet-cast lightweight veneer products use flexible latex molds, then the product can be easily removed after hardening, but shape variation occurs among units requiring mortar leveling
Solution Approach 1:
The patent applies parameter changes by transitioning from flexible latex molds to rigid steel or aluminum molds. This change in mold rigidity parameter ensures consistent shape and dimensional accuracy across all veneer units while still allowing for easy removal through proper design features like release agents or removable mold sections.
4Reliability
If wet-cast lightweight veneer products are installed using conventional multi-step system, then the installation meets structural requirements, but the process is time-consuming and requires skilled mason expertise
Solution Approach 1:
The patent applies segmentation by dividing the installation system into distinct functional components: a drainage plane layer for water management and an adhesive layer for bonding. This segmentation allows each layer to perform its specific function optimally while simplifying the overall installation process and reducing the need for skilled labor.
Solution Approach 2:
The patent applies universality by designing a multi-functional installation system where the drainage plane and adhesive layers work together to provide both structural integrity and water management. This integrated approach eliminates the need for separate mortar joints and skilled mason techniques, enabling faster installation by less skilled workers.
Data Source
AI summary
Described are dry cast lightweight veneer blocks and a system and method of installing lightweight veneer blocks. The courses can be assembled without mortar between the courses. As an example, sides of the veneer blocks have areas that recede from an imaginary plane between adjacent veneer blocks to give a deep texturing and a shadow effect between veneer blocks. The installation system and method include a substrate, an air barrier applied to the substrate, a plurality of veneer blocks, and an adhesive applied between the plurality of veneer blocks and the air barrier.