Foam Core Panels with Integrated Brackets for Lightweight Ceiling Structures
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Solution Overview
Problem
Existing ceiling structures for decorative and promotional purposes in retail environments are either heavy and costly to install and maintain for permanent displays, or complex and time-consuming to set up and tear down for temporary displays, disrupting customer experience and increasing labor and material costs.
Innovation Solution
A lightweight three-dimensional structure composed of foam core panels with flexible skins and internal brackets that can be easily assembled and disassembled, allowing for quick suspension and removal from ceilings, with slots and mitered surfaces for secure folding and attachment, reducing the need for extensive support systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If permanent ceiling structures are constructed using heavy materials and robust support systems, then structural strength and durability are improved, but installation cost and time increase
Solution Approach 1:
The patent changes the material parameter from heavy traditional materials to lightweight expanded poly苯乙烯 (EPS) foam core panels, achieving sufficient structural strength for temporary displays while dramatically reducing weight and installation requirements
Solution Approach 2:
The patent employs disposable-style lightweight foam panels with integrated brackets designed for temporary installation and easy removal, accepting limited reusability in exchange for drastically reduced installation cost and time
2Ease of operation
If temporary structures are designed for quick assembly and disassembly, then ease of installation is improved, but structural stability and durability worsen
Solution Approach 1:
The patent divides the ceiling structure into modular foam panels with integrated brackets that can be independently assembled and disassembled, enabling quick installation while maintaining stability through standardized connection interfaces
Solution Approach 2:
The patent combines foam core material with attached bracket elements to create a composite panel structure that integrates both the lightweight stabilizing core and the mechanical connection components into a single assembly unit
3Strength
If ceiling structures use extensive support systems and suspension mechanisms, then structural strength is improved, but device complexity increases
Solution Approach 1:
The patent merges the panel body and suspension bracket into a single integrated foam panel assembly, eliminating the need for separate support structures and simplifying the overall suspension system while maintaining adequate strength
4Adaptability or versatility
If temporary structures are frequently installed and removed, then adaptability is improved, but loss of time and labor costs increase
Solution Approach 1:
The patent incorporates pre-attached brackets directly onto the foam panels during manufacturing, so that when installation is needed, the panels are ready for immediate suspension without requiring additional assembly steps or preparation time
Data Source
AI summary
A structure is configured to be flat in an unassembled position and to form a three-dimensional structure in an assembled position. The structure includes a plurality of adjacent panels coupled together along fold lines with each panel including a foam core covered on one surface by a flexible skin. The flexible skin is continuous between the adjacent panels that are coupled together for forming a respective fold line for the adjacent panels to be brought together at a right angle to each other along the fold line. The foam core of each panel includes a mitered surface along abutting edges to form a miter joint when adjacent panels are brought together. Slots are formed in the panel cores adjacent to mitered surfaces. Brackets span a miter joint between adjacent panels, holding the spanned miter joint and panels together in a three-dimensional structure.