Adhesive Composite System for Stone Facades
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Solution Overview
Problem
Existing building facade systems with natural stone or ceramic tiles face challenges such as high energy loss due to thermal bridges formed by metallic fasteners, complex and time-consuming installation processes, and limitations in design flexibility due to static fastening requirements.
Innovation Solution
A composite system for fastening natural stone slabs or ceramic tiles directly to a supporting substrate using an adhesive layer system that eliminates the need for a metallic substructure, incorporating thermal insulation and reinforcement layers with alkali-resistant glass fibers and glass-aramid fibers to enhance stability and crack resistance, while minimizing thermal bridges and allowing for flexible design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic mechanical fasteners are used to attach natural stone slabs or ceramic tiles to the building wall, then the cladding elements can be securely fastened, but thermal bridges are formed between the thermal insulation layer and the supporting substrate, leading to increased energy loss
Solution Approach 1:
The patent removes the metallic mechanical fasteners from the system entirely, extracting the source of thermal bridges. Instead, it uses a composite adhesive layer system that provides both mechanical fastening and thermal insulation functions, eliminating the harmful thermal conduction path while maintaining fastening strength.
Solution Approach 2:
The patent employs a composite adhesive layer system consisting of multiple layers with different properties: a first adhesive layer for mechanical bonding, a thermal insulation layer for heat resistance, and a second adhesive layer for reinforcement. This composite structure combines the benefits of strong fastening with thermal insulation, resolving the contradiction between fastening strength and energy loss.
2Loss of energy
If thick thermal insulation layers are used to meet increasing heat insulation requirements, then thermal insulation performance is improved, but the mechanical fastening system becomes more complex and requires additional retaining elements
Solution Approach 1:
The patent merges the thermal insulation layer with the adhesive layer system, combining two previously separate functions into a unified structure. The thermal insulation layer serves dual purposes: providing heat insulation and acting as part of the mechanical fastening system through its adhesive bonds, thereby simplifying the overall fastening system while maintaining thick insulation.
Solution Approach 2:
The thermal insulation layer in the patent performs multiple functions simultaneously: it provides thermal insulation, acts as an adhesive bonding layer, and contributes to the mechanical strength of the fastening system. This multi-functionality eliminates the need for separate retaining elements, reducing fastening system complexity while maintaining insulation performance.
3Loss of energy
If a composite adhesive layer system with thermal insulation and reinforcement layers is used instead of metallic fasteners, then thermal bridges are eliminated and energy loss is reduced, but the adhesive system must provide sufficient mechanical strength to hold heavy natural stone slabs or ceramic tiles
Solution Approach 1:
The patent uses a composite adhesive layer system with multiple layers having different properties: the first adhesive layer provides initial mechanical bonding, the thermal insulation layer provides heat resistance and structural continuity, and the second adhesive layer with reinforcement fibers provides enhanced mechanical strength. This composite structure achieves both energy loss reduction and sufficient holding strength for heavy cladding elements.
Solution Approach 2:
The patent applies different material properties to different layers of the adhesive system: the first adhesive layer is optimized for bonding, the thermal insulation layer for heat resistance, and the second adhesive layer with reinforcement fibers for mechanical strength. This local optimization of material properties allows the system to simultaneously achieve energy efficiency and mechanical strength.
4Strength
If traditional mechanical fastening systems with L-shaped profiles and retaining elements are used, then the cladding elements can be securely attached, but the installation process becomes time-consuming and requires special safety precautions
Solution Approach 1:
The patent extracts the complex mechanical fastening components (L-shaped profiles, retaining brackets, multiple fastening points) from the system and replaces them with a simplified composite adhesive layer system. This reduction in component complexity directly reduces installation time and eliminates the need for special safety precautions while maintaining attachment security.
Solution Approach 2:
The patent replaces the complex mechanical fastening system with a chemical bonding system based on adhesive layers. This substitution eliminates the need for mechanical components and their associated installation complexity, reducing installation time while maintaining secure attachment through the bonded adhesive structure.
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
This solution reduces energy consumption by eliminating thermal bridges, simplifies the installation process, and offers design flexibility, achieving insulation values of 0.15 to 0.30 W/m²K and a long service life, even under freeze-thaw cycles, with reduced material costs and load requirements.
Implementation Method 1
a first adhesive layer system (20) which is adhered with its inside (26) to an outside (18) of a supporting substrate (12), a thermal insulation element (22) which is adhesively attached with its inside (30) to an outside (28) of the first adhesive layer system (20)
Implementation Method 2
thermal insulation element (22) for thermal insulation, achieving insulation values of 0.15 to 0.30 W/m²K and a long service life
Implementation Method 3
incorporating thermal insulation and reinforcement layers with alkali-resistant glass fibers and glass-aramid fibers to enhance stability and crack resistance
Data Source
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AI summary
An inventive building facade or roof with a composite system for fastening natural stone slabs (60) to an outer side (18) of a load-bearing substrate (12) comprising a first adhesive layer system (20) applied to the outer side (18) of the load-bearing substrate (12), a thermal insulation element (22) applied to an outer side (28) of the first adhesive layer system (20) and a second adhesive layer system (24) applied to an outer side (32) of the thermal insulation element (22), wherein the first adhesive layer system (20), the thermal insulation element (22) and the second adhesive layer system (24) form a thermal insulation composite system (16). According to the invention, the building facade or the building roof further comprises a panel adhesive layer system (52) applied to an outer side (50) of the second adhesive layer system (24) and natural stone panels (60) are applied to an outer side (56) of the panel adhesive layer system (52).