Masonry Veneer Brackets with Integral Air Gap
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Solution Overview
Problem
Masonry veneer systems require a scratch coat and lath system for installation, which adds cost, labor, and complexity, and is prone to human error and weather-related installation limitations, while panelized veneer products face issues with waste and design challenges due to their size and limited drainage plane gap.
Innovation Solution
A masonry veneer product with embedded brackets that secure to a building, creating an integral air gap for moisture escape, and a system that includes a weather-resistant barrier to prevent moisture entry, eliminating the need for a scratch coat and lath system, and allowing for efficient installation with reduced waste and improved durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a scratch coat and lath system is used for masonry veneer installation, then the veneer can be properly adhered to the building, but the installation process becomes more complex, costly, and time-consuming
Solution Approach 1:
The patent removes the scratch coat and lath components from the traditional veneer installation system. The veneer units are designed with integrated attachment features that directly secure to the building substrate, eliminating the need for these intermediate layers while maintaining reliable adhesion.
Solution Approach 2:
The attachment features are merged directly into the veneer units themselves, combining the functions of the veneer and its mounting system into a single integrated component. This eliminates the separate scratch coat and lath layers, simplifying the overall installation system.
2Strength
If a scratch coat and lath system is used, then proper structure is provided for cladding attachment, but additional labor and opportunities for human error increase
Solution Approach 1:
The patent extracts and eliminates the scratch coat and lath layers, removing the sources of installation complexity and human error. The veneer units directly attach to the building structure, reducing the number of installation steps and requirements.
Solution Approach 2:
The veneer units are designed with self-contained attachment features that enable them to secure to the building substrate without requiring external scratch coat or lath layers. This self-sufficient design simplifies installation and reduces dependency on skilled labor.
3Reliability
If the scratch coat must be applied and cured before veneer installation, then proper adhesion is achieved, but installation time is extended by up to 48 hours
Solution Approach 1:
The patent removes the scratch coat layer that requires curing time, eliminating the 48-hour delay. The veneer units attach directly to the building substrate without requiring this intermediate layer to cure, significantly reducing installation time.
Solution Approach 2:
The attachment features are pre-integrated into the veneer units during manufacturing, eliminating the need for on-site scratch coat application and curing. This preliminary preparation of attachment capabilities during fabrication removes the time delay associated with on-site curing.
4Productivity
If panelized veneer products are used, then installation efficiency is improved, but waste increases due to trimming requirements around penetrations and corners
Solution Approach 1:
The patent uses individual veneer units rather than large panelized products. This segmentation allows for flexible arrangement and minimal trimming around penetrations, windows, and corners, reducing material waste while maintaining installation efficiency through the simplified direct-attachment system.
Data Source
AI summary
A veneer product and system includes a body having an aesthetic front surface and a back surface for installation adjacent the building. The body has a top side and a bottom side and a bracket attached to body and projecting away from the back surface of the body, the bracket further comprising a first end adjacent the top side for attachment to the building and a first protrusion for positioning the back surface a predetermined distance from the building and a second end having a second protrusion for positioning the bottom of the back surface a predetermined distance from the building and a bottom projection adjacent the bottom side for engagement with a second body to retain the bottom end of the veneer product.