Flexible Prefabricated Facade System Resolving Brittle Material Cracking
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Solution Overview
Problem
Traditional methods of constructing building facades are time and labor intensive, requiring skilled labor and involving brittle materials that crack under deformation, while also lacking in flexibility and resistance to hydrodynamic forces.
Innovation Solution
A flexible prefabricated facade system comprising a supporting layer, surface elements, and filler, where all components are designed to be flexible, allowing for deformation without cracking and improved resistance to hydrodynamic forces, with the option of being rolled for transportation and installed with reduced on-site labor through pre-fabrication at a factory.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional masonry elements (bricks, slips) are used to form a facade, then the facade provides a traditional appearance and structural coverage, but the materials are brittle and will crack when deformed or subjected to handling stresses
Solution Approach 1:
The patent changes the physical state and mechanical properties of the facade materials from rigid and brittle (traditional masonry) to flexible and crack-resistant. The supporting layer, surface elements, and filler are all formulated to exhibit flexible characteristics that allow deformation without cracking, directly resolving the contradiction between maintaining structural integrity and resisting deformation.
Solution Approach 2:
The patent employs composite material structures where the supporting layer (flexible substrate), surface elements (decorative flexible components), and filler (flexible joint material) work together as an integrated flexible system. This composite approach enables the facade to maintain both appearance and structural performance while achieving flexibility and crack resistance that traditional homogeneous masonry cannot provide.
2Ease of operation
If traditional facade construction methods are used with individual slips and on-site pointing, then the facade can be customized and installed, but the process is time and labor intensive requiring skilled masonry labor
Solution Approach 1:
The patent applies preliminary action by pre-fabricating the entire facade assembly including the supporting layer, surface elements, and filler in a factory setting before installation. This pre-assembly eliminates the need for on-site pointing and complex masonry work, significantly reducing both installation time and the skill level required for installation while maintaining customization options.
Solution Approach 2:
The patent merges multiple separate components (supporting layer, surface elements, filler) into a single integrated prefabricated facade unit. This consolidation transforms what would traditionally require multiple sequential steps (attaching slips, then pointing joints) into a single installation operation, dramatically improving ease of operation and reducing time loss.
3Stability of the object's composition
If rigid supporting layers and filler materials are used in facade construction, then the structure provides stability, but the materials cannot flex and will crack under handling or installation stresses
Solution Approach 1:
The patent fundamentally changes the mechanical parameters of the supporting layer and filler from rigid to flexible. This parameter change enables the materials to adapt to deformation and handling stresses while maintaining structural stability through the flexible composite system, resolving the contradiction between stability and adaptability.
4Reliability
If traditional brittle facade materials are used, then the facade provides durability and appearance, but the materials will crack and fail under hydrodynamic forces and environmental stress
Solution Approach 1:
The patent changes the material parameters from brittle to flexible, enabling the facade to withstand hydrodynamic forces and environmental stress without cracking. The flexible supporting layer, surface elements, and filler work together to provide durability that is resistant to the harmful effects of water pressure, freezing, and thermal expansion.
Data Source
AI summary
A flexible prefabricated facade surface covering for installation on a surface of a structure includes a supporting layer, a plurality of surface elements connected to the supporting layer, and a filler provided between adjacent surface elements and connected to the supporting layer.