Curved Ceiling Sail with Interlocking Projections and Side Segments
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Solution Overview
Problem
Existing curved components for ceilings and walls face challenges such as complex connections, lack of additional fixation, and high manufacturing costs, making them difficult to assemble and adapt to environmental requirements.
Innovation Solution
A flexible arch plate with projections and holding sections that engage with an elongated side segment, providing additional fixation and allowing for easy assembly and adaptation, using materials like sheet metal or plastics that can be stamped or folded for cost-effectiveness and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If rigid edge pieces are used to create convex or concave curvature in ceiling sails, then the desired curved shape is achieved, but the connection between the ceiling sail and edge pieces becomes complex
Solution Approach 1:
The ceiling sail is divided into modular components: a flexible arch plate forming the curved surface, rigid side elements providing structural support, and connecting pieces joining them. This segmentation allows each component to be optimized independently - the arch plate for curvature and aesthetics, the side elements for rigidity, and the connectors for simple assembly.
Solution Approach 2:
Connecting pieces serve as intermediaries between the flexible arch plate and rigid side elements. These connectors simplify the joint by providing a standardized interface that accommodates both the flexibility of the arch plate and the rigidity of the side elements, eliminating complex direct connections.
2Reliability
If conventional fixation methods are used for side elements on arch plates, then basic attachment is achieved, but additional fixation is lacking
Solution Approach 1:
Multiple fixation functions are merged into the connecting pieces. Each connector simultaneously provides attachment to the arch plate, attachment to the side element, and positioning alignment. This combination of functions into a single component achieves reliable multi-point fixation without increasing overall structural complexity.
3Adaptability or versatility
If customized curved components are manufactured for different environments, then adaptability is improved, but manufacturing cost increases
Solution Approach 1:
The arch plate, side elements, and connecting pieces are designed as universal modular components that can be configured for different curved geometries and applications. By maintaining standardized interfaces and component designs, the system achieves adaptability to various environments without requiring custom manufacturing for each application, thereby controlling production costs.
Solution Approach 2:
Curved components are adapted to different environments by changing geometric parameters (curvature radius, length, angle) of the modular components rather than redesigning the entire structure. The flexible arch plate can be manufactured with different curvature parameters while maintaining the same basic component form and connection methods, enabling cost-effective customization.
4Stability of the object's composition
If complex connection systems are used for curved components, then structural stability is improved, but assembly ease deteriorates
Solution Approach 1:
The curved component system is segmented into discrete modular units (arch plates, side elements, connectors) that can be assembled in a standardized sequence. This segmentation transforms a complex monolithic structure into simple repeatable assembly steps, maintaining stability through modular interconnections rather than complex integrated joints.
Solution Approach 2:
The connecting pieces are pre-designed with integrated attachment features and positioning elements. This preliminary design of the connection mechanism allows workers to simply connect components without performing complex alignment or fastening operations during assembly, while still achieving stable structural connections.
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
The solution enables the creation of inexpensive, easy-to-manufacture, and adaptable curved components that can be easily assembled and customized for various environments, providing stable and aesthetically versatile solutions for ceiling and wall applications.
Implementation Method 1
the projections of the arch plate are formed by folding at an angle of 90° to the arch plate surface
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The element has a flexible arched plate (10) comprising two opposite side edges and a set of spaced-apart projections (11) extending upward from the arched plate. An elongate side segment (30) comprises an upper curved longitudinal edge and a lower curved longitudinal edge that faces the arched plate. The projections comprise a retaining portion, where the upper longitudinal edge of the side segment engages into the retaining portion in a form fit manner. A narrow web extends upward from the arched plate, where the projections merge with the narrow web. An independent claim is also included for a method for manufacturing a curved structural element.