Lightweight Masonry Mounting via Sliding Track Connector
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Solution Overview
Problem
Traditional cast-stone systems are heavy and require significant structural steel connections, making them inefficient for mounting lightweight architectural masonry units, which have complex geometrical constraints and lack reliable adhesive attachment mechanisms.
Innovation Solution
A connector assembly comprising an elongated track with slide channels, a connecting member with a base and flange portion, and a fixation member that allows for flexible and efficient mounting of lightweight architectural masonry units to a building support structure, using a combination of lightweight stone or stone-like shells and expanded polystyrene cores for improved thermal and structural performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional cast-stone systems are used, then structural strength is achieved, but weight becomes excessive and requires significant structural steel connections
Solution Approach 1:
The patent applies composite materials by combining lightweight stone or stone-like shell with expanded polystyrene (EPS) core to create a lightweight architectural masonry unit that maintains structural integrity while dramatically reducing weight compared to traditional solid cast stone
Solution Approach 2:
The patent changes the density parameter of the masonry unit by introducing EPS core material, transforming it from a dense solid structure to a lightweight composite structure with controlled density that provides both strength and weight reduction
2Ease of operation
If adhesive attachment is used for lightweight masonry units, then installation simplicity is improved, but reliability of attachment is insufficient
Solution Approach 1:
The patent introduces a connector assembly as an intermediary component between the lightweight masonry unit and the building support structure. This connector provides a reliable mechanical attachment mechanism that overcomes the insufficiency of direct adhesive attachment while maintaining installation simplicity
3Reliability
If split-tail connectors are used, then attachment capability is provided, but flexibility for complex geometrical constraints is insufficient
Solution Approach 1:
The connector assembly is designed with universal applicability to accommodate various complex geometrical constraints of lightweight architectural masonry units. The elongated track with adjustable positioning and multiple connection points provides flexibility for different installation scenarios while maintaining reliable attachment
Solution Approach 2:
The connector assembly incorporates dynamic adjustment capabilities through the elongated track design that allows positioning at different locations along the track length, enabling adaptation to complex geometrical constraints while maintaining secure attachment
4Strength
If traditional cast-stone mounting systems are used, then structural integrity is maintained, but installation efficiency and labor cost are reduced
Solution Approach 1:
The mounting system is segmented into distinct components: elongated track, connector, and fixation member. This segmentation allows for pre-assembly and simplified installation steps, improving installation efficiency while maintaining structural integrity through the coordinated function of each component
Data Source
AI summary
The present subject matter relates to systems, devices, and methods for mounting one or more lightweight architectural masonry units to a building support structure. An elongated track includes a web and opposed edge portions that form a pair of slide channels, the elongated track being configured to be mounted to the building support structure. A connecting member includes a base portion configured to retain the connecting member to the channels but is movable within the channels along the track, and a flange portion is configured to connect to a first lightweight architectural masonry unit of the one or more lightweight architectural masonry units. A fixation member includes a first end configured to connect to the elongated track and a second end configured to connect to the lightweight architectural masonry unit, the fixation member being configured to retain the first lightweight architectural masonry unit in place relative to the elongated track.