Construction Element for Large-Radius Wall Curves

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Solution Overview

Problem

Current construction elements make it difficult to create large-radius bends or curves around corners in building walls, particularly in residential construction, as existing products typically require wetting and bending of drywall and wooden studs to achieve desired curvature.

Innovation Solution

The introduction of a construction element with a corner-forming surface and fastener strip that can be easily attached to framing studs, allowing for the creation of large-radius curves without the need to wet and bend drywall or wooden studs, featuring a corner-forming surface that matches the wall panels and a fastener strip parallel to the studs for secure attachment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If traditional drywall and wooden studs are wetted and bent to create large-radius curves, then the desired curvature can be achieved, but the construction process becomes complex and time-consuming

Engineering Contradiction:

Improvecurvature radiusVSAvoidconstruction process complexity

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The construction element is divided into distinct functional segments: a curved outer surface for aesthetic appearance, a fastener strip for attachment, and an inner core for structural support. This segmentation allows each part to be optimized independently and simplifies the overall construction process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The construction element acts as an intermediary component between the wall panels and the studs. It provides a pre-formed curved surface that eliminates the need to bend drywall and studs, while still allowing secure attachment to the structural framework.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Shape

If traditional methods are used to create large-radius bends, then curvature can be achieved, but the construction time increases significantly

Engineering Contradiction:

Improvecurvature radiusVSAvoidconstruction speed

Core Design Contradiction:

ShapeVSProductivity

Solution Approach 1:

The curved surface and fastening features are prepared in advance during manufacturing. The construction element arrives at the job site ready-to-install, eliminating the need for on-site bending, wetting, and drying processes that significantly slow down traditional construction.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The complex mechanical process of wetting, bending, and drying drywall and studs is replaced by a simple mechanical attachment process. The pre-formed construction element is secured to studs using standard fasteners, dramatically reducing installation time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Shape

If drywall and studs are manipulated to create curves, then the desired shape can be achieved, but the risk of breaking and damage increases

Engineering Contradiction:

Improvecurvature radiusVSAvoidmaterial integrity

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The curved surface is extracted from the traditional drywall material and implemented as a separate, dedicated construction element. This eliminates the need to compromise the integrity of structural studs and drywall by bending them, as the curvature is provided by a specialized component designed for it.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The physical state and properties of the construction element are optimized for its specific function. The material composition and structural parameters are designed to provide the necessary curvature while maintaining strength and resistance to breaking, unlike standard drywall or wood studs.

Inventive Principle:

Principle #35Parameter changes

4Adaptability or versatility

If current construction elements are used, then simple corner protection is provided, but large-radius bends and curves cannot be created

Engineering Contradiction:

Improvecurvature capabilityVSAvoidcorner sharpness

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The construction element features an asymmetric design with a curved outer surface for aesthetic applications and a straight inner surface for structural attachment. This asymmetry allows the same element to provide both the desired large-radius curvature and precise alignment with wall panels and studs.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The construction element incorporates a curved or rounded outer surface that can provide large-radius bends and flowing corner transitions. This curvature is integrated into the element's geometry, allowing it to create soft, rounded corners while maintaining structural integrity and alignment capabilities.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Data Source

PatentUS11505946B2Construction elements

Publication Date: 2022.11.22 WOO DONALD KEW

AI summary

A construction element is provided for forming a corner of a surface of a building, the surface including wall panels attached to framing studs. The construction element includes: a corner-forming surface that that is shaped to extend, in a cross-sectional view, between two separate wall panels, such that ends of the corner-forming surface, as viewed in the cross-sectional view, substantially match respective corners of the wall panels; and a fastener strip that, in a state in which the corner-forming surface is in its installed position with respect to the framing studs, is substantially parallel to one or more of the framing studs, such that a fastener can attach the fastener strip to one or more of the studs without passing through the wall panel.