Flexible Cladding Wrap for Breathable Historic Facades
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Solution Overview
Problem
Current building cladding technologies are inefficient, wasteful, prone to cracking, and fail to match the aesthetic of historic or non-planar surfaces, leading to unnatural finishes and potential damp buildup in older buildings.
Innovation Solution
A flexible cladding wrap with a porous and absorbent facing layer made from recycled powdered aggregate bonded with a polymeric binding agent, allowing for a brick- or stone-work effect that can be applied to contoured surfaces, breathe through the underlying structure, and feature a flexible grouting layer for enhanced durability and weather resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If rigid panels are used for cladding, then the finish can be matched to the building, but the cladding cannot be applied to contoured or non-planar surfaces
Solution Approach 1:
The patent uses a flexible backing layer with a flexible facing layer containing powdered aggregate and polymeric binder. This flexible membrane structure can conform to contoured and non-planar surfaces while maintaining the desired brick- or stone-work aesthetic finish, resolving the contradiction between adaptability and structural rigidity
Solution Approach 2:
The cladding wrap combines multiple materials: a flexible backing substrate, a polymeric binding agent, and powdered aggregate (brick or stone particles). This composite structure provides both the flexibility needed for contoured surfaces and the rigid appearance of traditional masonry through the aggregate layer
2Productivity
If traditional brick cladding is used, then the aesthetic finish is natural, but the application process is laborious and time-consuming
Solution Approach 1:
The patent combines multiple functions into a single integrated wrap: the flexible backing layer provides structural support and conformability, while the flexible facing layer with powdered aggregate provides the brick- or stone-work appearance. This merged structure eliminates the need for separate bricklaying and grouting operations, significantly improving productivity and reducing installation complexity
Solution Approach 2:
The flexible facing layer with powdered aggregate creates a visual copy of traditional brick or stone masonry without requiring actual bricks. The polymeric binder holds the aggregate particles to form a realistic masonry appearance that can be applied rapidly as a continuous wrap rather than individual units
3Adaptability or versatility
If the facing layer is cured by heat and air, then the cladding remains porous and flexible, but the curing process requires additional equipment and time
Solution Approach 1:
The patent specifies curing the polymeric binder by exposure to heat and air, which changes the physical parameters of the binder (from liquid to solid) while maintaining the porosity and flexibility of the overall structure. This parameter change approach allows the facing layer to remain breathable and flexible unlike rigid cement-based alternatives
Solution Approach 2:
The flexible facing layer with powdered aggregate and polymeric binder is designed as a disposable cladding solution that is applied and then cured in situ. Once cured, it provides permanent cladding without requiring complex reusable forming or curing equipment, simplifying the overall system
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
The flexible cladding wrap provides a versatile, aesthetically pleasing façade that can be applied to non-planar surfaces, maintains the appearance of historic buildings, prevents damp buildup, and offers improved durability and weather resistance while reducing waste and environmental impact.
Implementation Method 1
the bonding of the powdered aggregate to the facing substrate being provided by way of a polymeric binding agent
Implementation Method 2
the facing layer with the powdered aggregate and polymeric binding agent is cured by application of heat and air
Implementation Method 3
an absorbent and porous flexible facing substrate
Data Source
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AI summary
A flexible cladding wrap (10) for an exterior or interior wall of a building, a building wall panel, and/or a building surface is provided, the flexible cladding wrap (10) comprising a flexible facing layer (16) including a, preferably absorbent and more preferably porous, flexible facing substrate (22) and powdered aggregate (24) bonded to the facing substrate (22); and a flexible backing layer (12) including a flexible backing substrate (20) to which the facing layer is attached. A system utilising said flexible cladding wrap (10) to create a continuous aesthetic impression of the building is also provided, in addition to methods of making and using said flexible cladding wrap (10).