Facade Panel Manufacturing with Rough Mass Seams
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Solution Overview
Problem
Existing methods for manufacturing facade panels with ceramic tiles or bricks face issues such as the need for foam gauze, which complicates the process and allows seam mass to be visible and prone to white rust, and the panels are not suitable for vertical installation once dried, as they require additional support for handling.
Innovation Solution
The method involves filling tile seams with a jagged rough mass, followed by a hardening seam mass that binds the tiles, and using attachment spikes on the back panel to secure the tiles, eliminating the need for foam gauze and allowing the panel to be hung on a wall once processed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If foam gauze is used to prevent seam mass from penetrating to the bottom panel, then the seam mass is contained, but the process complexity increases and separate extra seam works are required
Solution Approach 1:
A rough mass layer is introduced as an intermediary substance between the seam mass and the bottom panel. This rough mass serves as a mediator that prevents the seam mass from directly contacting and penetrating to the bottom panel, eliminating the need for foam gauze while maintaining containment functionality.
Solution Approach 2:
The foam gauze component is extracted and removed from the manufacturing process. The patent replaces it with a rough mass layer that is integrated into the seaming process itself, simplifying the overall process by eliminating the separate foam gauze installation step.
2Reliability
If foam gauze is used to prevent seam mass from gripping to the bottom panel, then the seam mass is contained, but additional materials and separate operations are required
Solution Approach 1:
The rough mass layer combines multiple functions into a single substance: it serves as both the seam filling material and the barrier layer that prevents seam mass from gripping to the bottom panel. This merging eliminates the need for separate foam gauze material and separate application operations.
Solution Approach 2:
The rough mass layer is applied as part of the normal seaming process, and it automatically performs the barrier function without requiring additional materials or operations. The seam mass itself, when applied over the rough mass, creates the necessary containment and anti-gripping effects.
3Manufacturing precision
If ordinary seam mass is used to fill tile seams, then the seams are filled, but the seam mass can be seen outwards and white rust penetrates through
Solution Approach 1:
The rough mass layer creates a localized quality difference at the seam interface. The irregular surface structure of the rough mass provides a specific zone that prevents white rust penetration while allowing the seam mass to be properly contained and filled, addressing the harmful effects locally at the critical interface region.
4Ease of manufacture
If the panel is manufactured without attachment spikes on the back panel, then the manufacturing process is simpler, but the panel cannot be hung vertically on a wall
Solution Approach 1:
Attachment spikes are pre-formed as integral parts of the back panel during the manufacturing process. This preliminary action ensures that the panel is ready for vertical wall installation without requiring additional attachment components or steps, maintaining manufacturing simplicity while enabling versatile installation.
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 reduces the complexity of the manufacturing process, prevents seam mass from penetrating to the bottom panel, enhances the appearance of seams, and enables the panel to be installed vertically without additional support, maintaining structural integrity and appearance.
Implementation Method 1
a jagged rough mass, such as glass or stone chips having a granular size of 0,5 - 4 mm... is used as the first seaming agent. A layer of 3 - 5 mm rough mass is set on the bottom of the seam whereupon it will be a layer that is visible outwards... this seam mass penetrates to the needed amount of rough mass binding it, but it does not penetrate through the rough mass till the bottom panel of the mould
Implementation Method 2
attachment spikes that belong to said back panel become penetrated into the seams between the tiles and with the help of them tiling and the back panel are bound with each other
Implementation Method 3
tilled with a hardening seam mass that binds the tiles the back panel is pressed on top of tiles
Data Source
Figure 1
Figure 2
AI summary
Manufacturing method of a fasade panel meant for the outer lining of a building in which tiling (4) forming the outer surface of the mentioned panel is formed onto the surface of the back panel (5) meant to be the background of the fasade panel, tiling is attached to the mentioned back panel and the seams between the tiles are seamed with the help of a seam mass whereupon a mould (1) equipped with a bottom panel (13) is used in the manufacturing method on top of which a tile controller (2) is set, such as a net to adjust the locations of the tiles positioned upside down and finally the back panel (5) is pressed on top of tiles whereupon attachment spikes (8) that belong to the back panel (5) become penetrated into the seams between the tiles and with the help of them tiling and the back panel (5) are bound with each other. The tile seams are filled with a jagged rough mass placed against the back panel (13) of the mould (1) and after that are filled with a hardening seam mass that binds tiles into which seam mass also the attachment spikes (8) of the back panel (5) become penetrated when the back panel (5) is installed to its location.