Pre-formed Insert Body for Building Panel Aperture Reduction
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Solution Overview
Problem
Existing methods for reducing the size of apertures through building panels, such as those for lighting fixtures or conduits, often result in weak joints that can fail over time, leading to issues like cracked plaster or paint due to the use of in-fill materials and joint tapes.
Innovation Solution
A body with an inner and outer surface, featuring a recessed region and rim structure that can be inserted into existing apertures to alter their size or shape, providing a strong and stable connection using a frangible connection system and material application surfaces for concealing materials like plaster.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If in-fill materials and joint tapes are used to reduce aperture size, then the aperture size can be reduced, but the joint region becomes weak and may fail over time
Solution Approach 1:
The insert body is divided into multiple functional segments: an outer surface for engagement with the existing aperture, an inner surface defining the reduced aperture, a rear face for support, and a front face with recessed regions. This segmentation allows each part to perform its specific function optimally while maintaining overall structural integrity.
Solution Approach 2:
The insert body appears to be constructed as a composite structure combining rigid materials for structural support with recessed regions designed to receive concealing materials. This composite approach creates a strong joint region that integrates the insert with the surrounding panel structure.
2Area of stationary object
If in-fill materials are used to reduce aperture size, then the aperture can be reduced, but the concealing material may crack or fail
Solution Approach 1:
The recessed regions are pre-formed in the front face of the insert body, creating prepared receptacles for concealing materials before installation. This preliminary action ensures proper positioning and integration of concealing materials, preventing cracks and failures that would occur with improper application.
Solution Approach 2:
The front face features localized recessed regions with specific geometries tailored for receiving concealing materials. These recessed areas provide localized structural support and accommodation for the concealing material, ensuring its integrity while maintaining the reduced aperture opening.
3Ease of manufacture
If a simple in-fill approach is used, then the process is simple, but the joint region weakens over time
Solution Approach 1:
The insert body merges multiple functions into a single integrated component: aperture reduction, structural support through the rear face, and integration of concealing materials through front face recesses. This merging eliminates the need for separate in-fill materials and joint tapes, providing both simplicity of installation and long-term durability.
Data Source
AI summary
An insert body used in an existing aperture within a building panel, the body defining an aperture with geometry varied relative to the existing aperture, and comprising an inner surface, an outer surface, a front face and a rear face. The inner surface provides an inner side wall of the aperture to be formed, the outer surface provides for an outer side wall of the aperture to be formed and/or of the existing aperture to be varied. The outer side wall in use is located adjacent to the existing aperture side wall. The rear face provides a support surface for location upon the second face of the panel. The inner side wall terminates in at least one rim on the front face. The front face comprises at least one recessed region and each rim having a surface projected from the recessed region as a reference relative to the first face.