Modular facade fastening system with standardized grid supports
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Solution Overview
Problem
Existing fastening systems for building facade panels are complex, costly, and inefficient, requiring project-specific production, leading to increased assembly time, material waste, and potential safety issues due to limited length and accuracy limitations of hook rail systems.
Innovation Solution
A modular fastening system comprising standardized fastening fittings and grid carriers that can be easily assembled and adjusted, eliminating the need for project-specific components, allowing for flexible facade layouts and reducing material usage and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hook-rail systems are used with project-specific manufacturing, then the fastening system can be adapted to specific facade layouts, but the production time and cost increase significantly
Solution Approach 1:
The system divides the fastening function into separate components: standardized rails with uniform spacing and independent fastening elements that can be positioned at different locations. This segmentation allows the rails to be manufactured in advance with standard spacing, while the fastening elements can be independently positioned to match any facade layout, eliminating the need for custom manufacturing of entire rail assemblies.
Solution Approach 2:
The standardized rails are designed with universal compatibility - they can be used with different fastening elements and accommodate various facade panel types and layouts. The rails serve multiple functions: providing structural support, enabling adjustable fastening positions, and allowing easy replacement or modification of individual components without affecting the entire system.
2Manufacturing precision
If hook-rail systems are limited to 3 meters in length, then manufacturing accuracy can be maintained, but the positioning effort and complexity increase for longer facade sections
Solution Approach 1:
The system uses multiple short rail segments with standardized spacing rather than one long custom-manufactured rail. Each segment can be manufactured with high precision using standard punching operations, and the segments are connected using standardized coupling elements. This eliminates the need for multiple punching operations on long rails, maintaining manufacturing accuracy while reducing positioning effort through modular assembly.
Solution Approach 2:
The rails are manufactured in advance with pre-determined hook positions at standard intervals. The fastening elements are pre-positioned according to the specific facade layout requirements. This preliminary preparation of components with standardized dimensions and positions allows for quick on-site assembly without complex measurements or custom manufacturing, reducing both manufacturing complexity and positioning effort.
3Ease of manufacture
If continuous punching operations are used for long rails, then manufacturing can be simplified, but positioning inaccuracies and safety issues occur
Solution Approach 1:
Instead of performing continuous punching operations on long rails which accumulate positioning errors, the system uses multiple short rail segments that are each punched with standard, precise spacing. The segments are then connected using standardized coupling elements with built-in tolerance compensation. This segmentation maintains manufacturing precision while simplifying the punching process for each individual segment.
Solution Approach 2:
Standardized coupling elements serve as intermediaries between rail segments. These couplings incorporate tolerance compensation mechanisms that absorb positioning variations, ensuring that the overall rail assembly maintains the required geometric accuracy even though individual segments were manufactured separately with standard tolerances. This intermediary component mediates between the simplified segmented manufacturing process and the required overall precision.
4Productivity
If standardized components are used instead of project-specific rails, then production efficiency and cost decrease, but the ability to handle complex facade layouts is reduced
Solution Approach 1:
The system segments the fastening function into standardized rails with uniform spacing and independent adjustable fastening elements. The standardized rails can be manufactured efficiently in advance using automated punching operations, achieving high production efficiency. The independent fastening elements can then be positioned and attached at any location along the rails to accommodate complex facade layouts, maintaining design flexibility without requiring custom rail manufacturing.
Solution Approach 2:
The system introduces adjustability and flexibility through movable and repositionable fastening elements that can be located at different positions along the standardized rails. This dynamic configuration capability allows the same standardized components to adapt to various facade layouts and design requirements, maintaining versatility while benefiting from the production efficiency of standardized manufacturing.
Data Source
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AI summary
The invention relates to an attachment fitting (1) and to a grid support (2) of a modular fastening system for building facade panels (9). The attachment fitting (1) has at least one connecting element (4) that can be connected to a connecting receptacle, the shape of which corresponds to the connection element (4), on the rear side of the facade panel (9). The height (H) of the attachment fitting is smaller than the modular vertical grid (M) of the façade system, wherein the attachment fitting (1) can be brought into engagement with the grid support (2) in a form-fitting manner, which grid support (2) has a regular longitudinal grid. The invention makes it possible to replace traditional rail systems, which have to be manufactured in a project-specific manner, with a modular system of attachment fittings (1) which are positioned on standardized grid supports (2) without additional fastening elements. Any facade layouts can be realized, including mixed grids and panel blanks, without the need for prefabrication of elements for the facade substructure, in particular project-specific support rails. Material savings and quality and safety improvements at the construction site are achieved, and existing rail-length restrictions no longer apply. The risk for the builder is reduced, since no project-related prefabrication of rail systems and no additional delivery of specific individual parts are required.