Flexible Porous Cladding for Non-Planar Surfaces
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Solution Overview
Problem
Current cladding technologies for buildings are inflexible, wasteful, prone to cracking, and difficult to apply on non-planar surfaces, leading to unnatural finishes and potential delamination due to moisture issues.
Innovation Solution
A method of forming a flexible facing layer using a porous support substrate with a wet mixture of powdered aggregate and binding agent, applied in a template to create flexible tile slips that can be easily applied and adapted to uneven surfaces, allowing for a breathable and aesthetically matching brick- or stone-work effect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rigid panels are used for cladding, then the finish can be matched to the building, but the cladding cannot be applied to non-planar surfaces or surfaces in disrepair
Solution Approach 1:
The patent uses flexible thin sheets as the base material for the cladding system. These sheets can conform to non-planar surfaces and surfaces in disrepair while maintaining the desired finish. The flexibility allows the cladding to adapt to various surface conditions without requiring rigid panel construction.
Solution Approach 2:
The cladding is divided into multiple individual tiles that can be independently applied to the surface. This segmentation allows each tile to conform to local surface variations while collectively providing a matched finish across the entire surface. The modular approach enables adaptation to non-planar surfaces.
2Ease of manufacture
If separate tiles are used for cladding, then the application is modular, but the process becomes laborious and requires additional spacers for alignment
Solution Approach 1:
The patent merges multiple tiles into a single integrated flexible sheet structure. The tiles are pre-arranged and connected on the flexible base, eliminating the need for separate handling, alignment, and spacers during application. This combining reduces installation time and labor while maintaining modular benefits.
3Reliability
If moisture-trapping cladding is used, then the structure is protected from weather, but ice expansion causes delamination during freezing weather
Solution Approach 1:
The patent incorporates porous materials in the cladding structure that allow moisture to pass through rather than become trapped. This porosity prevents the buildup of water that would otherwise freeze and expand, eliminating the cause of delamination while maintaining weather protection capabilities.
Solution Approach 2:
The patent converts the potentially harmful effect of moisture accumulation into a beneficial feature by designing the cladding to actively manage and channel moisture through its structure. The moisture pathway becomes a designed feature rather than a defect, preventing freezing damage while maintaining protective function.
4Manufacturing precision
If traditional cladding materials are used, then the appearance can be achieved, but the materials crack and fade rapidly due to seasonal climate change
Solution Approach 1:
The patent uses composite materials that combine the aesthetic properties of traditional cladding materials with the durability and climate resistance of modern synthetic materials. This composite construction maintains the desired appearance while significantly improving resistance to cracking and fading from seasonal climate variations.
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 facing layer provides a versatile, durable, and weather-resistant cladding solution that can be applied to non-planar surfaces, maintaining the building's appearance while preventing moisture buildup and delamination, and can be easily stored and transported.
Implementation Method 1
the flexible porous support substrate allows for it to be adhered to non-planar surfaces
Implementation Method 2
a wet mixture of powdered aggregate and binding agent
Data Source
Figure 1~2
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AI summary
A method of forming a visible flexible facing layer (10) for creating a visible appearance of a facing wall-surface of a walled structure (14), comprises the steps of: a] providing a flexible porous support substrate (18) on a support (16); and b] creating a wet mixture (32) using a powdered aggregate (34) formed at least in part from solid particulate material and mixed with a binding agent. A further step c] applies the wet mixture (32) to the flexible support substrate (18) using a control template (24) to form a plurality of spaced-apart wall-tile slips (26) which at least in part permeate the flexible porous support substrate (18); and step d] cures the wall-tile slips (26) to the flexible porous support substrate (18) to form a tile sheet of the visible flexible facing layer (10) having flexible wall-tile slips (26). A step e] folds the visible flexible facing layer (10) for storage and/or transportation. A method of matching or substantially matching existing brick- or stone-work of a wall of a building to a visible flexible facing layer, and a visible flexible facing layer for creating a visible appearance of a facing wall- surface of a walled structure and formed using one or either said method are also provided.