Planar Façade System with Cast Edge Profile
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Solution Overview
Problem
Existing facade systems are labor-intensive to manufacture and lack adequate mechanical protection, especially for sensitive thermal insulation, and do not provide a satisfactory visual impression.
Innovation Solution
A facade system comprising a prefabricated surface support element with a cast-on edge protection profile that forms a watertight connection with a cover layer, providing both static and weather protection, and using a method that eliminates the need for additional formwork elements during production by forming a groove on the carrier element and filling it with hardening cast material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional plaster protective layers are applied to insulation elements, then mechanical protection is provided, but the solution is very labor intensive and does not offer adequate mechanical protection
Solution Approach 1:
The patent combines the insulation element, cover layer, and edge protection profile into a single prefabricated facade element. The edge protection profile is cast directly onto the carrier element in a factory setting, merging multiple protective functions into one integrated component that requires no additional on-site labor for application.
Solution Approach 2:
The edge protection profile is cast onto the carrier element during factory production before the facade element is installed on the building. This preliminary protective measure is already in place before the element reaches the construction site, eliminating the need for additional labor-intensive protective measures during installation.
2Strength
If a cast-on edge protection profile is provided on the carrier element, then mechanical protection and watertight connection are enhanced, but the device complexity increases
Solution Approach 1:
The edge protection profile is cast directly onto the carrier element using a simple groove-filling process with hardening cast material. This integrates the protection function into the existing carrier element structure without requiring separate complex protective components or additional assembly steps.
3Device complexity
If the carrier element is left exposed without protection, then the structure is simpler, but the carrier element is vulnerable to mechanical stresses during transport and assembly
Solution Approach 1:
The edge protection profile is cast onto the carrier element during factory production, providing mechanical protection before the element undergoes transport and on-site assembly. This preliminary protective measure prevents damage during handling and installation without requiring complex protective packaging or additional protective steps later.
4Productivity
If the cover layer is applied before the edge protection profile, then production steps can be simplified, but the watertight connection may be compromised
Solution Approach 1:
The edge protection profile is cast onto the carrier element first, creating a protected edge structure. The cover layer is then applied in a subsequent step, ensuring that the edge protection profile remains intact and can form a reliable watertight connection with the cover layer without being compromised by the covering process.
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 reduces production costs and assembly complexity, enhances mechanical protection, and improves the visual appearance of the facade system while ensuring watertightness and diffusion openness, making it suitable for both rear-ventilated and non-rear-ventilated applications.
Implementation Method 1
Pouring the groove with a hardening cast material, in particular cast plastic, to form a cast facade element
Data Source
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AI summary
The present invention relates to a planar façade element or similar surface element, which can be installed in prefabricated form to a structure (1) by way of corresponding installation means to form a façade (2) or similar wall or ceiling surface (3), comprising a planar carrier element (6), and a, particularly waterproof, cover layer (8), which is or can be disposed on at least one front (9) of the carrier element (6), wherein an edge protection profile (10) is provided, which is cast on at least one front (11) of the carrier element (6) in a statically effective manner and is configured such that the cover layer (8) is connected to the edge protection profile (10), or can be connected to the same, in a watertight connection. The invention further relates to a method for the production of such a façade element. The invention further relates to a façade system or similar wall or ceiling system, comprising at least two planar façade elements of the type mentioned above, which can be installed on a structure (1) adjacent to each other to form a façade (2) or similar wall or ceiling surface (3), wherein the edge protection profiles (10) cast at least on the fronts (11) of the two carrier elements (6) facing each other are connected to each other by means of an adhesive bond (26). The invention also relates to a method for the production of such a façade system.