Corrugated Felt Wall Element With Vertex Connections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of multi-layered felt wall elements is technically challenging due to the complexity of cutting processes, and existing solutions do not easily allow for adaptation in thickness or fabrication safety.
Innovation Solution
A three-layered felt panel composition featuring a plane top and bottom layer with a corrugated middle layer, where the corrugated layer connects at vertex points, avoiding full-surface connections and enabling easy fabrication and thickness adjustment, with optional additional corrugated layers for enhanced rigidity and properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If full-surface connections between felt layers are used, then structural integrity is improved, but fabrication complexity and material buildup increase
Solution Approach 1:
The connection between felt layers is segmented from full-surface contact to discrete line-shaped connections along vertex lines. The corrugated middle layer creates specific contact zones at its wave peaks and valleys, dividing the connection area into segmented lines rather than continuous surfaces, thereby simplifying fabrication while maintaining structural integrity.
Solution Approach 2:
The connection interface is transformed from two-dimensional full-surface contact to one-dimensional line-shaped connections. The corrugated structure introduces a third dimension (vertical undulations) that naturally creates line contacts at vertex lines when layers are pressed together, reducing complexity without sacrificing strength.
2Use of energy by moving object
If multiple felt layers are added to increase thickness, then insulation performance is improved, but material buildup and handling difficulty increase
Solution Approach 1:
The multilayer structure is segmented into repeating units of corrugated middle layers between plane outer layers. Each corrugated layer acts as an independent insulating unit with air pockets, providing cumulative insulation performance while the line-shaped connections prevent excessive material buildup that would complicate handling.
Solution Approach 2:
The corrugated felt layers create porous structures with air pockets between the waves, enhancing thermal insulation performance. The porous architecture provides insulation without requiring excessive material thickness, maintaining handling ease while improving energy performance.
3Ease of manufacture
If corrugated felt layers are oriented parallel to each other, then manufacturing simplicity is improved, but bending rigidity in multiple directions is reduced
Solution Approach 1:
The corrugated layers are oriented asymmetrically relative to each other, with vertex lines of adjacent corrugated layers offset in position. This asymmetric arrangement creates a more complex three-dimensional structure that enhances bending rigidity in multiple directions while remaining manufacturable through simple layering and pressing operations.
Data Source
AI summary
The invention concerns a wall element including a felt panel that has at least two felt layers, with at least one felt layer having a three-dimensional structure on at least one top side. The felt panel includes as its top layer a plane felt layer, as its bottom layer a plane felt layer, and as its middle layer at least one corrugated felt layer. The corrugated felt layer bordering on the top layer is connected to the top layer on its top side in the region of upper vertex lines or vertex points formed by its wave peaks. The corrugated felt layer bordering on the bottom layer is connected to the bottom layer on its bottom side in the region of lower vertex lines or vertex points formed by its wave valleys.