Compressible Rib Panel for Masonry Dimensional Tolerance

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Solution Overview

Problem

Existing masonry wall systems face challenges in accommodating artificial masonry units with dimensions varying from standard dimensions, as units larger than standard size deform ribs, making installation difficult, and units smaller than standard size lack sufficient interlocking to be retained in the panel.

Innovation Solution

A masonry wall system comprising panels with compressible projections and masonry units featuring teeth that compress these projections, allowing for the accommodation of units with varying heights by compressing cavities within the projections, and spacers for handling multiple units efficiently.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If standard rigid ribs are used to retain masonry units, then structural strength is improved, but units with dimensional variations (±3-5 mm) cannot be accommodated

Engineering Contradiction:

Improvestructural strengthVSAvoidaccommodation of dimensional variations

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The patent changes the physical state of the ribs from rigid to compressible/resilient. The ribs are made of elastomeric material that can deform under compression to accommodate masonry units with dimensional variations of ±3-5 mm, while still providing sufficient retaining force. This parameter change allows the same rib structure to adapt to different unit sizes without compromising structural integrity.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The compressible ribs act as a cushioning element that anticipates and absorbs dimensional variations in masonry units before installation problems occur. The resiliency of the ribs provides a buffer zone that accommodates size variations, preventing installation difficulties and ensuring proper retention of units regardless of their exact dimensions.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Adaptability or versatility

If compressible material is used for ribs, then adaptability to dimensional variations is improved, but retention force may be insufficient

Engineering Contradiction:

Improveaccommodation of dimensional variationsVSAvoidretention force

Core Design Contradiction:

Adaptability or versatilityVSForce

Solution Approach 1:

The panel system uses a composite construction combining rigid structural elements (panel body, reinforcement) with compressible elastomeric ribs. This composite approach allows the ribs to provide both the necessary compliance for dimensional variations and sufficient retention force through their elastic properties. The elastomeric material is selected to balance softness for accommodation with hardness for retention.

Inventive Principle:

Principle #40Composite materials

3Force

If tight interlocking is used to retain small units, then retention force is improved, but installation difficulty increases

Engineering Contradiction:

Improveretention forceVSAvoidinstallation ease

Core Design Contradiction:

ForceVSEase of operation

Solution Approach 1:

The rib system transitions from a static rigid structure to a dynamic compressible element. During installation, the ribs can be compressed to accommodate units easily, then rebound to provide retention force. This dynamic behavior allows both easy installation and strong retention without requiring tight interlocking that would make installation difficult.

Inventive Principle:

Principle #15Dynamics

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

Enables the secure retention of masonry units with heights differing by up to ±5 mm between ribs, improving installation ease and reducing the need for adhesive materials, while allowing for flexible handling and clamping during manufacturing.

Implementation Method 1

Each rib has compressible projections projecting from its bottom side, and each projection has a cavity therein, the cavity providing resiliency to the projection

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

the cavity providing resiliency to the projection

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS9556618B2Panel with compressible projections and masonry wall system including the panel

Publication Date: 2017.01.31 OLDCASTLE BUILDING PRODUCTS CANADA INC

AI summary

A wall panel, a masonry wall system, and a method are described. Masonry units are used with wall panels to make a masonry wall. The wall panel has a back face and a front face. The front face has multiple ribs which engage the masonry units, where each rib has top and bottom sides. The bottom sides of the ribs have multiple compressible projections with cavities which can be deformed so as to retain the masonry unit in the panel. Each masonry unit has a body with a front face, a back face, and top and lateral faces. The back face and top lateral face form a back peripheral edge, and the top lateral face has at least one tooth for securing the masonry unit in the panel. In operation, the tooth compresses the projections of the horizontal ribs, thereby securing the masonry unit in the panel.