Polymeric Mat Façade Substrate Corrosion Resistance
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Solution Overview
Problem
Conventional building façade constructions using wire mesh are prone to corrosion due to environmental exposure and galvanic corrosion, leading to deterioration and potential accidents, with existing systems failing to adequately address these issues.
Innovation Solution
A corrosion-resistant building façade system utilizing a highly porous three-dimensional matrix filamentous polymeric mat and a fiberglass mesh layer, which are heat bonded together to provide a substrate for façade elements, replacing conventional wire mesh and enhancing durability and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire mesh is used as substrate for façade construction, then the façade can be securely associated with the building wall, but corrosion occurs leading to deterioration and potential accidents
Solution Approach 1:
The patent removes the problematic wire mesh component from the façade system and replaces it with a corrosion-resistant polymeric mesh. This extraction of the harmful element (metal mesh prone to corrosion) while maintaining the essential function of providing structural support and securing the façade to the building wall.
Solution Approach 2:
The patent employs a composite material system consisting of a polymeric mesh combined with adhesive layers and façade panels. The polymeric mesh serves as the substrate, replacing traditional metal mesh, and the combination of these materials creates a corrosion-resistant composite structure that maintains structural integrity while eliminating galvanic corrosion issues.
2Strength
If conventional wire mesh is used, then façade material can be supported, but galvanic corrosion cells are created due to dissimilar metals
Solution Approach 1:
The patent changes the material parameter of the mesh substrate from metal to polymer, fundamentally altering the electrochemical properties of the system. This parameter change eliminates the galvanic corrosion mechanism by removing the conductive metal component that would otherwise create galvanic cells when in contact with other dissimilar metals in the façade assembly.
3Reliability
If wire mesh is used between building wall and façade material, then façade can be securely associated with building wall, but corrosion causes expansive force that cracks façade material
Solution Approach 1:
The patent extracts the rusting metal mesh from the system and replaces it with a non-corrosive polymeric mesh. This elimination of the corrosive element prevents the expansion and cracking problems that occur when steel mesh rusts, while maintaining the secure attachment function between the building wall and façade material through the polymeric mesh and adhesive system.
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 significantly reduces corrosion-based deterioration, maintains structural integrity, and simplifies façade construction while reducing the risk of injury and external noise penetration, offering improved durability and safety compared to traditional methods.
Implementation Method 1
a fiberglass mesh layer having a first face and a second face, wherein the fiberglass mesh layer first face is heat bonded to the polymeric mat second face
Data Source
AI summary
A building façade system adapted to be installed onto an exposed surface of a building and provide a substrate for installation of façade elements (e.g., stone, stucco and the like). The system preferably provides a corrosion-resistant structure adapted to withstand extended environmental exposure. In general, the system includes a highly porous three dimensional matrix filamentous polymeric mat and a fiberglass mesh layer associated therewith. Collectively, the polymeric mat and fiberglass mesh layer are adapted to be installed onto an exposed building wall and provide a substrate onto which desired façade elements may be installed.