3D Building Surface Panel Layout for Seamless Assembly
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Solution Overview
Problem
Existing methods for using solid surface materials in building surfaces, such as walls and ceilings, are labor-intensive, expensive, and difficult to install seamlessly, especially when creating three-dimensional designs, due to challenges in aligning and concealing seams between material units.
Innovation Solution
A computer-aided method that partitions a three-dimensional design into segments based on the dimensions of the surface material units, generating milling instructions for cutting and assembling these units to create a seamless, non-repeating design, allowing for efficient and cost-effective installation by low-skilled workers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If solid surface material is used to create three-dimensional building surfaces, then design flexibility and aesthetic quality are improved, but installation complexity and labor cost increase significantly
Solution Approach 1:
The building surface is divided into multiple modular panels that can be independently manufactured and assembled. Each panel contains portions of the three-dimensional design, and they are joined together to form the complete surface. This segmentation allows complex designs to be broken down into manageable units that are easier to install while maintaining overall design integrity.
Solution Approach 2:
The three-dimensional design is pre-partitioned into segments and panel layouts are predetermined before installation. Computer algorithms automatically generate optimal panel configurations and seam locations that align with the design features, eliminating the need for complex on-site measurements and adjustments during installation.
2Shape
If solid surface material units are cut and assembled to create three-dimensional designs, then design complexity and ornamentation are improved, but seam concealment difficulty increases
Solution Approach 1:
The panel segments are designed with varying levels of three-dimensional complexity distributed across their surfaces. Areas with prominent design features are positioned away from seam lines, while simpler regions are placed near seams. This local variation in design complexity ensures that seams are positioned in less visually critical areas, making them easier to conceal.
Solution Approach 2:
The seam lines themselves are designed as transitional elements that incorporate design features or matching patterns from adjacent panels. By making the seams part of the overall design rather than separate defects, they blend into the ornate surface patterns and become less noticeable.
3Manufacturing precision
If expert installers perform extensive sanding to conceal seams, then seam visibility is reduced, but installation time and labor cost increase
Solution Approach 1:
The panel segments are designed with self-aligning features such as interlocking edges, guide rails, or magnetic attachments that automatically position panels correctly during assembly. The design geometry itself provides alignment cues that guide installers in positioning panels with proper seam alignment without requiring extensive manual sanding or adjustment.
Solution Approach 2:
The seam tolerance parameters are optimized based on viewing distances and lighting conditions. By calculating acceptable seam gap dimensions that remain invisible under normal viewing conditions, the system allows for faster installation with relaxed precision requirements, eliminating the need for time-consuming fine-tuning.
4Adaptability or versatility
If traditional tile-based three-dimensional surfaces are used, then design repetition is avoided, but installation time and cost increase
Solution Approach 1:
A single modular panel system serves multiple functions: it provides the base surface, incorporates the three-dimensional design, enables easy assembly through standardized connections, and allows for seamless integration of different design patterns. This universal panel design replaces multiple specialized components (tiles, grout, mounting hardware) with a single integrated solution that accelerates installation.
Data Source
AI summary
A method implemented by a computer system, the computer-implemented method comprising receiving dimensions of a building surface, including a surface length and a surface height; receiving dimensions of a surface material unit, including a material length and a material height; receiving design parameters defining a three-dimensional design over the building surface; partitioning the three-dimensional design into a plurality of three-dimensional segments based on both the three-dimensional design and the dimensions of the surface material; and generating a set of milling instructions for cutting a plurality of surface material units into the plurality of three-dimensional segments.