Modular Lattice Wall Cladding for Continuous Plaster Adhesion
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Solution Overview
Problem
Existing wall overcladding systems face challenges in ensuring the adhesion and stability of insulating layers to the wall, often resulting in discontinuous plaster layers, thermal bridges, and the need for additional reinforcing meshes, which complicates the application process and increases costs.
Innovation Solution
A modular insulating and reinforced covering system featuring a three-dimensional lattice structure that is completely buried in the cement plaster, providing a continuous and thick plaster layer with integrated fixing elements, ensuring full contact with the wall and eliminating the need for additional reinforcing meshes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a thin cement plaster layer (a few millimetres) is applied to the insulating layer, then the application process is simple and quick, but the adhesion and stability of the covering to the wall cannot be guaranteed over time
Solution Approach 1:
The invention transitions from a two-dimensional flat plaster application to a three-dimensional structured system using a lattice framework with vertical spacers. This adds the vertical dimension (thickness control) and spatial dimension (reinforcement distribution), allowing the plaster to be contained within a defined volume between the lattice planes, thereby improving adhesion and stability while maintaining application efficiency.
Solution Approach 2:
The lattice structure provides localized reinforcement at specific points and regions where needed most for adhesion and stability. The spacers create localized hollow spaces that ensure uniform plaster distribution and contact with the insulating layer, while the overall system maintains a relatively thin profile. This localized quality enhancement resolves the contradiction between thin-layer simplicity and long-term reliability.
2Reliability
If additional reinforcing meshes and special supports are added to ensure stability, then the adhesion and structural integrity improve, but the application process becomes extremely complicated and expensive
Solution Approach 1:
The invention merges multiple functions into a single integrated lattice structure: reinforcement (metallic mesh), thickness control (spacers), and plaster containment (three-dimensional framework). Instead of applying separate reinforcing meshes and supports in multiple steps, the lattice provides all these functions simultaneously, dramatically simplifying the application process while maintaining structural stability.
Solution Approach 2:
The lattice structure serves multiple purposes: it reinforces the plaster layer, defines the hollow space for plaster containment, provides spacing from the insulating layer, and creates a framework for uniform plaster distribution. This multi-functionality eliminates the need for separate special supports and reinforcing elements, reducing application complexity while ensuring structural integrity.
3Strength
If the plaster layer is made discontinuous to allow for lattice structure, then the lattice can be embedded for reinforcement, but the thermal insulation performance deteriorates due to thermal bridges
Solution Approach 1:
The lattice structure creates a controlled porous or hollow space within the plaster layer, where air (a thermal insulator) is trapped between the lattice planes. This hollow space filled with plaster maintains thermal insulation performance while the lattice framework provides reinforcement. The structure avoids continuous metallic thermal bridges by using the hollow space configuration.
4Reliability
If a thick plaster layer is applied to ensure continuous coverage and adhesion, then the thermal inertia and mechanical resistance improve, but the application process requires additional reinforcing elements and becomes more complex
Solution Approach 1:
The lattice structure is pre-assembled with spacers attached before plaster application. This preliminary configuration establishes the hollow space and reinforcement framework in advance, allowing the plaster to be applied uniformly within the defined boundaries. The preliminary action of creating the lattice framework eliminates the need for additional reinforcing elements during or after plaster application, simplifying the overall process while ensuring continuous coverage.
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 achieves a stable, continuous cement plaster layer with enhanced mechanical, acoustic, and fire resistance, simplifying the application process, improving thermal inertia, and allowing for the use of common building equipment, while preventing cracks and ensuring structural stability.
Implementation Method 1
at least one insulating layer directly or indirectly in contact with the wall to be covered, said insulating layer being constituted by one or more insulating modular panels
Implementation Method 2
at least one layer of cement plaster, positioned in such a way that it adheres to said insulating layer
Data Source
Figure 1
Figure 1a
Figure 1b
AI summary
The invention is a covering (R) for walls (M), comprising an insulating layer, a layer of cement plaster (C) incorporating a layer made up of modular lattices (1, 1') defining a counteracting plane (B) that is spaced from the insulating layer, projections or protrusions or spacer elements in general (R, R1, 21, 22, 23, P21) positioned between said lattices (1, 1') and the insulating layer and defining a hollow space filled with said layer of cement plaster (C), fixing means (3) suited to constrain said lattices (1, 1') to said wall (M). The system that is the subject of the invention achieves several important results, such as: refurbishment of already existing overcladding, improved heat insulation, improved resistance to fire, high mechanical performance, improved acoustic insulation, improved anti- seismic properties, easy and quick application with reduced costs, optimal finishing of the plaster.