Facade Structure with Insulating Layer and Spacers
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Solution Overview
Problem
Existing facade structures face challenges such as time- and cost-intensive installation, visually unpleasant adhesive bleeding, size limitations for tile elements, and undesirable thermal bridges due to metal support systems, which also allow rainwater penetration and affect the appearance.
Innovation Solution
The use of insulating panels with fabric or fleece coatings for stable attachment, sealed butt joints, and spacers with fabric or fleece for ventilation and joint material retention, along with a non-cement, silane-modified adhesive for large-format tile elements, eliminates the need for additional support systems and prevents adhesive bleeding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal support systems with anchors are used to mount tile elements, then the tile covering can be ventilated from behind and mechanically secured, but thermal bridges are created, rainwater penetration occurs, appearance is affected, and cost increases
Solution Approach 1:
The invention extracts and eliminates the metal support system from the facade structure, mounting tile elements directly to the insulating layer without anchors or brackets that penetrate the insulation, thereby preventing thermal bridges while maintaining mechanical securing through adhesive bonding
Solution Approach 2:
The invention merges the mounting function directly into the insulating layer by applying adhesive to the back of tile elements and pressing them directly onto the insulating layer, combining the structural support and insulation functions into a single integrated system
2Strength
If reinforced inner wall is applied before mounting tile elements, then mechanical strength and stability are improved, but installation time and cost increase significantly
Solution Approach 1:
The invention extracts and eliminates the reinforced inner wall layer from the facade structure, achieving mechanical strength directly through the adhesive bonding between tile elements and the insulating layer, which is already structurally integrated with the load-bearing wall
Solution Approach 2:
The invention merges the structural reinforcement function into the insulating layer itself, which is already mechanically connected to the load-bearing wall, eliminating the need for a separate reinforced inner wall layer and reducing installation steps
3Strength
If cement-like tile adhesive is applied to entire surface, then strong bonding is achieved, but plastics and calcium carbonate bleed out causing visually unpleasant deposits
Solution Approach 1:
The invention applies adhesive locally in specific patterns (such as peripheral application or discrete bonding zones) rather than covering the entire surface, providing sufficient bonding strength at critical locations while preventing excessive adhesive that could bleed out and cause visual deposits
Solution Approach 2:
The invention changes the application parameters of the adhesive, using appropriate adhesive quantity, viscosity, and application method to achieve strong bonding without excess material that would bleed out, thereby preventing calcium carbonate and plastic deposits
4Ease of operation
If tile elements with large format sizes are used, then fewer joints and better appearance are achieved, but conventional standards prohibit their use on insulating layers
Solution Approach 1:
The invention changes the bonding parameters by using area-wide adhesive application with appropriate adhesive strength and flexibility, enabling large-format tile elements to be reliably mounted on insulating layers without violating structural requirements, thus allowing fewer joints and better appearance
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 approach results in a cost-effective, well-ventilated, and visually appealing facade structure with sealed joints, preventing rainwater penetration and allowing for larger tile formats without thermal bridges.
Implementation Method 1
an adhesive or mortar for fastening the insulating panels to the load-bearing underground of the facade structure can cling very well to the fabric or fleece, resulting in a very stable attachment
Implementation Method 2
Such a reinforcing and/or sealing layer counteracts any warpage of the insulating panels and/or penetration of moisture or vapour
Implementation Method 3
adhesive is designed to be elastic and is applied to the tile elements and/or the insulating layer in point or row-like fashion
Data Source
AI summary
A method for manufacturing a facade structure includes fastening to a load-bearing underground of a facade a dimensionally stable insulating layer having a supporting outer surface. Spacers of the same height are fastened to the insulating layer such that the spacers protrude outward from the insulating layer. An elastic adhesive is applied at points and/or as rows onto the insulating layer and/or the tile elements in areas in which no spacers are disposed, the height of the applied adhesive being greater than the height of the spacers. The tile elements are adhered to the insulating layer by pressing the tile elements against the spacers, whereby hollow spaces remain between the tile elements and the insulating layer due to the point-like and/or rows of applied adhesive.