Wall Construction with Flanged Face Panels
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Solution Overview
Problem
Existing wall construction methods using interlocking hollow blocks and modular panels do not fully leverage injection molded components to streamline the construction process, often requiring multiple phases and additional finishing steps.
Innovation Solution
A kit comprising face panels with perpendicularly extending flanges and snap-straps or fasteners for assembling a hollow block structure, allowing for efficient assembly and integration of multiple construction phases into a single phase, with options for using recycled materials and various fastening methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional interlocking hollow blocks or modular panels are used for wall construction, then the structural integrity and wall formation are achieved, but multiple construction phases and additional finishing steps are required, increasing construction time and complexity
Solution Approach 1:
The patent combines multiple construction phases into a single integrated system. The face panels with attached flanges and fasteners merge the functions of wall paneling, structural connection, and finishing into one assembly process, eliminating separate phases for structural assembly and finishing work
Solution Approach 2:
The face panels serve multiple functions simultaneously: they provide the wall surface, incorporate attachment flanges for structural connection, and include integrated fastening mechanisms. This multi-functionality reduces the number of separate components and construction steps needed
2Adaptability or versatility
If multiple separate components are used for wall assembly, then flexibility and adaptability are improved, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The wall system is segmented into modular face panels with integrated flanges and fasteners. Each panel is a self-contained unit that can be independently manufactured and assembled, providing flexibility while simplifying the overall assembly process through standardized components
Solution Approach 2:
The flanges and fasteners are pre-attached to the face panels during manufacturing. This preliminary action eliminates the need for separate attachment operations during assembly, simplifying the construction process while maintaining adaptability through modular panel design
Data Source
AI summary
A kit for forming a hollow block assembly to be used to construct a wall, the kit consisting of two face panels and a plurality of fasteners, each face panel comprising a plurality of spaced apart flanges extending perpendicularly from and attached to each panel so that a hollow block structure is assembled when the flanges of the face panels are connected together, directly or indirectly, by the fasteners.