Veneer Panel Corner Mounting System
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Solution Overview
Problem
The installation of pre-fabricated stone or brick veneer panels is time-consuming and limited in versatility, particularly for harder-to-fit areas like edges and corners, due to their large sizes and the need for specialized masonry skills.
Innovation Solution
The development of a veneer panel with a mounting system that allows for on-site trimming and features a J-shaped fastening member, flange, and connecting rib configuration, enabling efficient installation on various surfaces, including corners, through a snap-in joint mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pre-fabricated stone or brick veneer panels are used, then material costs and labor costs are reduced compared to natural stones, but installation remains time-consuming and labor-intensive
Solution Approach 1:
The veneer panel is divided into multiple smaller segments or modules that can be easily handled and installed. The panel includes integrated mounting features that segment the installation process into simple, repetitive steps, allowing workers to install panels quickly without specialized masonry skills.
Solution Approach 2:
Mounting features such as fastening members, flanges, and connecting ribs are pre-integrated into the veneer panels during manufacturing. This preliminary action eliminates the need for on-site preparation or specialized installation techniques, allowing workers to simply attach panels to the substrate using the pre-built mounting system.
2Productivity
If larger sizes of pre-fabricated veneer panels are used, then fewer panels are needed to cover a surface, but versatility for harder-to-fit areas such as edges or corners is limited
Solution Approach 1:
The mounting system is designed to be universally applicable to various installation scenarios including flat surfaces, corners, edges, and irregular areas. The flange and connecting rib configuration can be oriented and positioned to accommodate different geometries, allowing the same panel type to be used throughout the entire project without needing specialized corner pieces.
Solution Approach 2:
The mounting features are designed to be flexible in their application. The flange can be positioned at different locations on the panel, and the connecting ribs can be oriented to match various substrate configurations. This dynamic adaptability allows workers to adjust the installation approach for each specific location while using the same panel and mounting system.
3Reliability
If traditional mounting methods are used, then secure attachment is achieved, but specialized masonry skills are required and installation is laborious
Solution Approach 1:
The mounting system is designed to be self-explanatory and self-installing. The flange fits into corresponding recesses or attaches to mounting strips in an intuitive manner, and the connecting ribs automatically align with substrate features. This self-service design eliminates the need for specialized masonry knowledge, allowing any worker to install the panels securely by following simple procedures.
Solution Approach 2:
The mounting system acts as an intermediary between the veneer panel and the substrate. Rather than requiring direct attachment skills, workers simply need to attach the panel to the mounting features (flange and connecting ribs), which then securely connect to the substrate. This intermediary system simplifies the installation process while maintaining secure attachment.
Data Source
AI summary
The invention provides a veneer panel for use on a surface of a building. The veneer panel can be fabricated with a mounting system that includes a frame and/or a backing for efficient installation on a building surface, as well as a mounting strip or mating connector that can be installed on a building surface to further support the veneer panel.