Stone Strip Wall Cladding With Plaster Ribs
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Solution Overview
Problem
Traditional methods for cladding walls with stone strips are labor-intensive, require skilled professionals, and result in uneven joints and material wastage due to sagging strips and expensive, vulnerable insulation panels with ribs that prevent reinforcement mesh application.
Innovation Solution
A method involving a reinforcement mesh, a layer of plaster with impression moulds creating parallel ribs, and pressing stone strips into adhesive mortar between the ribs to prevent sagging and align strips easily, allowing for a smooth plaster application without ribs for reinforcement mesh integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional plaster mounting method is used, then stone strips can be applied to the wall, but the stone strips sag under their own weight causing uneven joints and messy appearance
Solution Approach 1:
The patent applies preliminary action by creating support ribs in the plaster layer before mounting the stone strips. These ribs are formed by pressing an impression mould into wet plaster, creating a structured support framework that prevents sagging before the strips are applied. This preliminary structuring of the mounting surface ensures stable positioning and straight joints.
2Ease of operation
If insulation panels with milled ribs are used, then stone strip alignment is simplified, but material wastage increases due to milling process
Solution Approach 1:
The patent extracts the rib-forming function from the insulation panel manufacturing process and separates it into a distinct step using an impression mould pressed into plaster. This allows the ribs to be created only where needed for support, rather than milling ribs into entire insulation panels, thereby reducing material wastage while maintaining the alignment function.
3Manufacturing precision
If insulation panels with ribs are used, then stone strip positioning is improved, but the ribs are vulnerable during application and prevent reinforcement mesh mounting
Solution Approach 1:
The patent introduces the impression mould as an intermediary tool that temporarily shapes the plaster to create ribs, then is removed after the plaster cures. The cured plaster ribs themselves become the stable support structure, eliminating the vulnerability of pre-formed panel ribs while maintaining positioning precision. The reinforcement mesh is applied to the flat plaster surface before rib formation, avoiding conflicts with vulnerable ribs.
4Ease of manufacture
If traditional manual levelling method is used, then stone strips can be mounted, but labor intensity increases and requires experienced professionals
Solution Approach 1:
The patent applies self-service by creating a self-aligning system where the cured plaster ribs automatically provide support and positioning for the stone strips. The ribs are spaced to match the strip width, causing strips to naturally align between them without requiring manual levelling or skilled intervention. This self-service positioning system dramatically reduces labor intensity and simplifies the mounting 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
Reduces labor and skill requirements, prevents material wastage, ensures straight joints, and allows for easy reinforcement mesh application, with ribs hidden in the joints and excess adhesive mortar escape, facilitating a more efficient and aesthetically pleasing wall cladding process.
Implementation Method 1
pressing the impression mould into the still wet plaster, such that the wet plaster penetrates into the grooves of the impression mould to form parallel ribs
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
Method for cladding a wall (7) with stone strips (8), with the following steps: - applying a layer of plaster (13); - providing an impression mould (1) with parallel grooves (6) ; - pressing the impression mould (1) into the still wet plaster (13), such that the wet plaster (13) penetrates into the grooves (6) of the impression mould (1) to form parallel ribs (17); - removing the impression mould (1) after full or partial curing of the plaster (13), such that a plaster structure with parallel ribs (17) remains against the wall (7); - applying an adhesive mortar (18) directly between the ribs (17) and/or to the base (19) of the stone strips (8); - pressing the stone strips (8) into the still wet adhesive mortar (18) between the ribs (17), whereby the superfluous adhesive mortar (18) can escape through the gap (20) between the stone strip (8) and the ribs (7); - optional pointing of the gaps (20) between the stone strips (8) with jointing mortar (22).