Modular Façade Panel with Ceramic Insulation and Stone Finish
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Solution Overview
Problem
Traditional façade insulation systems face issues with slow assembly, high visibility of support profiles, limited surface finishes, high costs due to complex substructures, and risk of cracking from grouting, while lacking versatility and effective fire resistance.
Innovation Solution
A compound modular panel system featuring a thin ceramic insulation layer, high-density extruded polystyrene core, and natural stone or slate outer layer, secured using a twin-component adhesive and L-shaped metal mooring straps, allowing for a robust, versatile, and fire-resistant façade or roof enclosure with reduced manpower and risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If insulating panels are bolted on to lateral tabs of vertical beams to bear weight and wind pressure, then the panels can support their own weight and external loads, but the assembly becomes slower and requires more complex support structures
Solution Approach 1:
The patent combines the support function and the finishing function into a single integrated profile system. The aluminum profiles serve both as structural support elements and as visible finishing elements, eliminating the need for separate support structures and accelerating assembly while maintaining load-bearing capacity through optimized profile design
2Ease of manufacture
If horizontal beams are assembled on the outer face of vertical beams, then the panel support structure can be assembled, but the general thickness of the device becomes considerable and support profiles become visible
Solution Approach 1:
The patent transitions from a three-dimensional bulky support structure to a two-dimensional thin-profile system by designing integrated aluminum profiles that provide structural support within a minimized thickness envelope, making profiles either invisible or aesthetically acceptable while maintaining assembly feasibility
3Reliability
If traditional ventilation façade systems use complex substructure of profiles and moorings, then fire propagation can be prevented through mandatory firebreaks, but the system cost increases significantly
Solution Approach 1:
The patent employs composite aluminum profiles that integrate multiple functions (structural support, thermal insulation, fire barrier, and finishing) into single multi-functional elements, reducing overall system complexity while maintaining fire resistance through carefully designed profile compositions and firebreak integration
4Ease of manufacture
If grouting is used for panel finishing, then the façade can be completed, but cracking risks increase and surface finishes are limited
Solution Approach 1:
The patent replaces the mechanical grouting system with a integrated panel system where panels are mechanically fixed to aluminum profiles, eliminating grout joints and associated cracking risks while enabling diverse surface finishes through the panel materials themselves rather than through grout applications
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 system provides high insulation yield, reduces assembly time, and offers a homogeneous finish, improved fire safety, and environmental sustainability, while being lightweight and capable of withstanding impacts, with no risk of cracking or fire propagation.
Implementation Method 1
a layer of thin ceramic insulation (7) consisting of a liquid ceramic compound based on spherical micrograms of four types of special ceramics
Implementation Method 2
The core (6) consists of a module of insulating material, consisting of high-density extruded polystyrene
Implementation Method 3
The outer wall of the panel (9) consists of a fine laminated strip of natural stone or slate joined to the panel core (6) using a twin-component viscous adhesive (7) based on epoxy resin
Data Source
Figure 1
AI summary
A PANEL FOR THE ENCLOSURE AND EXTERNAL THERMAL INSULATION OF FAÇADES AND ROOFS, AND THE INSTALLATION PROCEDURE, based on the application of a compound modular panel secured to the original façade or the existing support of the building using specific profiles, characterised because the base panel consists of a fine inner layer of ceramic insulation (7), a panel core (6) comprising a wall of insulating material formed by high-density extruded "XPS" polystyrene approximately 100 mm thick, and an outer wall of the panel (9) of fine strips of natural stone or slate joined to the core of the panel (6) with special viscous adhesive (7) and with full self-supporting capacity, compact and fire-resistant.