Polymer Cladding with Mesh and Insulation for Brick Aesthetics

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Solution Overview

Problem

Conventional clay brick finishes are expensive, offer poor insulation, and lack fire-resistant properties and ease of installation in wall cladding systems.

Innovation Solution

Polymer-based exterior wall cladding systems featuring simulated bricks with a polymeric core, reinforcing mesh, and layered coatings for insulation, fire resistance, and aesthetic appeal, including a basecoat and finish layer, and offset portions for uniform spacing and additional insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If conventional clay brick is used for wall cladding, then aesthetic appearance is achieved, but insulation performance deteriorates

Engineering Contradiction:

Improveaesthetic appearanceVSAvoidinsulation performance

Core Design Contradiction:

ShapeVSLoss of energy

Solution Approach 1:

The patent employs a composite material system consisting of a polymeric core member with integrated insulation boards, combined with mesh layer and basecoat/finish layers. This composite structure achieves both the aesthetic appearance of clay brick and improved insulation performance, as the polymeric core and insulation boards work together to reduce energy loss while the outer layers provide the desired visual appearance.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent implements a nested structure where insulation boards are integrated within the polymeric core member, and the mesh layer and basecoat/finish layers are sequentially applied over the core. This nested arrangement allows the insulation functionality to be embedded within the structural and aesthetic layers, achieving both thermal efficiency and visual appeal in a single integrated component.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Shape

If conventional clay brick is used for wall cladding, then aesthetic appearance is achieved, but fire resistance deteriorates

Engineering Contradiction:

Improveaesthetic appearanceVSAvoidfire resistance

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The patent uses a composite material system where the polymeric core member is combined with mesh layer and basecoat/finish layers. This composite structure achieves both the aesthetic appearance of clay brick and improved fire resistance, as the layered composite construction provides enhanced fire-resistant properties compared to conventional clay brick.

Inventive Principle:

Principle #40Composite materials

3Shape

If conventional clay brick is used for wall cladding, then aesthetic appearance is achieved, but installation complexity increases

Engineering Contradiction:

Improveaesthetic appearanceVSAvoidinstallation ease

Core Design Contradiction:

ShapeVSEase of operation

Solution Approach 1:

The patent divides the wall cladding system into modular simulated brick units, each comprising a polymeric core member with integrated insulation and outer layers. These standardized modular units can be manufactured with consistent dimensions and features, enabling simplified installation procedures compared to conventional clay brick, while maintaining the desired aesthetic appearance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent incorporates insulation boards and structural features directly into the polymeric core member during manufacturing, before installation. This preliminary integration of insulation and structural elements eliminates the need for separate installation steps, thereby simplifying the overall installation process while achieving the desired aesthetic appearance.

Inventive Principle:

Principle #10Preliminary action

4Shape

If conventional clay brick is used for wall cladding, then aesthetic appearance is achieved, but cost increases

Engineering Contradiction:

Improveaesthetic appearanceVSAvoidcost

Core Design Contradiction:

ShapeVSQuantity of substance

Solution Approach 1:

The patent employs a polymeric core member as a cost-effective alternative to conventional clay brick. The polymeric material and integrated insulation boards provide a more economical solution than traditional clay brick, achieving the desired aesthetic appearance at reduced material and installation costs.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent uses a composite material system combining polymeric core member with integrated insulation boards and outer layers. This composite construction achieves the aesthetic appearance of clay brick while reducing overall cost through the use of more economical materials and simplified installation requirements.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS10208485B2Building material cladding components and methods

Publication Date: 2019.02.19 TREMCO CPG INC

AI summary

A starter board for a wall cladding system includes a core member and a laminate. The core member defines a board profile portion including parallel, planar base and outer surfaces defining a uniform thickness, the base surface extending from a first lateral surface to a second lateral surface, and a supporting flange portion extending outward from the planar outer surface, at the second lateral surface, to an outer surface of the flange portion. The laminate includes a reinforcing mesh and a basecoat layer covering the reinforcing mesh, and covers the second lateral surface of the board profile portion, the inner and outer lateral surfaces of the supporting flange portion, the outer surface of the supporting flange portion, and portions of the base and outer surfaces of the board profile portion proximate the supporting flange portion.