Insulated Decorative Wall Panel With Embedded Brackets
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Solution Overview
Problem
Traditional modular wall panels often lack the natural appearance of stone or brick, are heavy, and difficult to install, particularly for less experienced craftsmen.
Innovation Solution
A modular panel design featuring a panel block with embedded brackets and a lighter weight foam insulator block, allowing for secure and aligned installation, with a decorative front resembling natural stone or brick.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional modular panels are used to create wall treatments, then installation is simplified compared to natural stone, but the panels remain heavy and difficult to install for less experienced craftsmen
Solution Approach 1:
The panel combines a cementitious panel block with a foam insulator block to create a composite structure that reduces overall weight while maintaining structural integrity and adding insulation functionality
Solution Approach 2:
The panel is divided into distinct functional segments: a cementitious panel block for structural support and decoration, and a separate foam insulator block for thermal insulation and weight reduction, which are then integrated into a single assembly
2Productivity
If traditional modular panels are used for wall treatment, then labor intensity is reduced compared to natural stone, but the panels lack natural appearance and have linear uniformity
Solution Approach 1:
The front surface of the panel block is given a decorative finish that mimics natural stone or brick texture and appearance, while the back portion uses smooth cementitious material for structural purposes, creating different qualities in different locations of the same panel
3Manufacturing precision
If embedded brackets are added to panels for alignment and securing, then installation precision is improved, but device complexity increases
Solution Approach 1:
The brackets are integrated directly into the panel block during the casting process, merging the bracket function with the panel structure itself rather than being separate components that need to be attached later, thereby simplifying the overall device while maintaining precision
4Weight of moving object
If foam insulator block is embedded in panel block, then weight is reduced and insulation is provided, but manufacturing complexity increases
Solution Approach 1:
The foam insulator block is positioned and embedded within the panel block during the casting process before the cementitious material sets, performing the insulation integration action in advance rather than requiring post-manufacturing assembly steps
Data Source
AI summary
An insulated panel for a wall treatment and a method of manufacture thereof. The panel includes a panel block cast from a material. During casting, a first bracket, a second bracket, and an insulator block are partially embedded within the material. The insulator block, which is a lighter weight foam material, is embedded between the first and second brackets such that part of the insulator block will extend beyond a rear of the panel block once cast. Once cast, part of the first bracket extends upwardly beyond a top of the panel block and part of the second bracket angles downwardly and outwardly from the rear of the panel block and a distance below the insulator block. The second bracket is used to align the panel on a support surface. The first bracket is used to secure the panel to the support surface.