Masonry Slip Frame Interlocks for Durable Prefabricated Facades
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing prefabricated masonry façade panels face issues with adhesive-based systems failing due to temperature variations and mechanical systems requiring exact fitting, leading to increased costs and construction delays, and are prone to damage during transportation.
Innovation Solution
A masonry framework with elongate channels and lips that securely hold masonry slips using slots, allowing for prefabrication off-site and easy installation on-site, ensuring precise alignment and reducing panel weight and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive-based systems are used to bond brick slips to back panel, then manufacturing is simplified, but reliability deteriorates due to temperature variations causing bond failure
Solution Approach 1:
The patent replaces adhesive bonding with a mechanical interlocking system where metal ties or clips engage with slots in the brick slips. This mechanical system provides reliable attachment that is not affected by temperature variations, solving the reliability issue while maintaining ease of manufacture through standardized components.
2Reliability
If mechanical ties or clips are used to secure brick slips, then reliability improves, but adaptability deteriorates as panels cannot be adjusted after manufacturing
Solution Approach 1:
The patent incorporates adjustable mechanisms in the mechanical tie system that allow post-manufacturing adjustment of panel positions and configurations. This dynamic capability enables adaptation to unforeseen construction conditions while maintaining the reliable mechanical attachment provided by the interlocking mechanism.
Solution Approach 2:
The patent divides the masonry façade into modular panels with standardized mechanical attachment interfaces. This segmentation allows individual panels to be adjusted or replaced independently, providing adaptability while maintaining overall structural integrity through the reliable mechanical connection system.
3Strength
If prefabricated panels are made heavy for structural stability, then strength improves, but ease of operation deteriorates due to difficulty in transportation and installation
Solution Approach 1:
The patent uses composite construction combining lightweight materials for the panel body with separate structural reinforcement elements. This allows the panel to achieve necessary strength while minimizing weight, improving transportation ease. The mechanical tie system provides structural stability without requiring the entire panel to be heavy.
4Productivity
If prefabricated panels are transported as-is, then productivity improves, but object-generated harmful factors worsen due to damage to slips during transportation
Solution Approach 1:
The patent incorporates protective features in the mechanical tie system and panel construction that prevent damage to masonry slips during transportation and handling. The interlocking mechanism and protective coatings or coverings integrated into the design cushion and protect the slips, allowing panels to be transported as-is without risk of damage.
Data Source
AI summary
The present disclosure relates to a system of providing a façade wall for a building. In particular, the disclosure presents a series of frames and frameworks which are adapted to integrate with a number of different designs of masonry slips. These masonry slips are parts of bricks, or other building items and the like, which by means of appropriately placed slots can integrate and be held by lips and extensions on the frames. Corner units, soffit panelling and free standing archways are also possible by appropriate combination of the concepts described herein.