Non-welded Coping Caps Using Adhesive and Mesh
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Solution Overview
Problem
Current metal coping systems for buildings face challenges in seamlessly joining at corners without visible fasteners, welding, or soldering, which affects aesthetics and weather tightness, and post-painted solutions are costly and inefficient.
Innovation Solution
A method of forming coping caps and transitions using prefinished sheet metal without welds or solder, employing adhesive and reinforcing materials on the underside to create secure, waterproof joints that maintain the prefinished appearance and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding or soldering is used to join metal coping sections at corners, then the joint strength is improved, but discoloration and aesthetic appearance deteriorate
Solution Approach 1:
The harmful welding or soldering process is extracted and removed from the joining method. Instead, the patent uses mechanical fastening systems with concealed fasteners that achieve joint strength without thermal processes that cause discoloration, thereby maintaining the prefinished appearance of the metal coping sections
Solution Approach 2:
Concealed fasteners and sealing components serve as intermediaries between the metal coping sections. These intermediaries provide the necessary joint strength and weather sealing without exposing the visible surface to discoloration, allowing the prefinished appearance to be maintained while achieving strong connections
2Ease of operation
If exposed mechanical fasteners are used to secure coping sections, then the installation ease is improved, but the aesthetic appearance deteriorates due to visible fasteners
Solution Approach 1:
The visible portion of mechanical fasteners is extracted and removed from the exterior surface. The fastening system uses concealed fasteners that are hidden within the coping section profile or behind decorative elements, maintaining aesthetic appearance while preserving the ease of mechanical installation
Solution Approach 2:
Decorative cover elements or integrated concealed fastener systems serve as intermediaries that hide the mechanical fastening components from view. These intermediaries allow exposed fasteners to be used for installation ease while preventing the aesthetic deterioration caused by visible fasteners
3Shape
If post-painting is applied to welded or fastened joints, then the aesthetic appearance is improved, but the manufacturing cost and complexity increase
Solution Approach 1:
The metal coping sections are prefinished with paint or coating before assembly. This preliminary action ensures that the entire surface, including joint areas, receives a uniform finish during manufacturing, eliminating the need for complex post-assembly painting operations and reducing manufacturing complexity
Solution Approach 2:
The post-painting operation is extracted and removed from the manufacturing process. By using concealed fasteners and proper joint design, the need for post-assembly painting is eliminated, simplifying the manufacturing process while maintaining aesthetic appearance through the prefinished surface
4Manufacturing precision
If sheet metal joints are made visible at corners, then the manufacturing precision is reduced, but the aesthetic appearance deteriorates
Solution Approach 1:
The visible sheet metal joint is extracted and hidden within the coping section profile. The joint is positioned on the interior or concealed surfaces, removing it from view while allowing standard manufacturing tolerances to be maintained without the pressure of achieving visually perfect seams
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 solution provides a strong, durable, and aesthetically consistent coping system that eliminates discoloration issues and reduces material and labor costs associated with post-painting, while maintaining the benefits of continuous coil coating.
Implementation Method 1
employing adhesive and reinforcing materials on the underside to create secure, waterproof joints
Implementation Method 2
seal the wall cavity from moisture infiltration and 'wind washing'
Data Source
AI summary
A design and fabrication technique whereby a coping cap and/or transition can be supplied with mitered corner sections and other transitional components which utilize the identical prefinished or bare sheet metal material(s) without any reliance on exposed mechanical fasteners, welding, soldering, or post-applied paints. This is essentially accomplished by joining the pre-finished sheet material(s) together using a mesh screen and adhesive on the underside (non-exposed) face of the sheet material(s).