Interconnectable Composite Panels With Periodic Protrusions

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Solution Overview

Problem

Construction processes face challenges in accurately fitting building elements due to dimensional variations, leading to increased installation time and mess, especially when adapting materials like wood or concrete, and existing solutions are limited in versatility and prone to gaps or require precise pre-knowledge of corner positions.

Innovation Solution

A composite construction panel kit featuring interconnectable panel elements with periodic protrusions and recesses, allowing for easy assembly and adaptation to fit various building elements, including formwork for concrete, which can be securely attached without removing the formwork and enables quick, clean installation with minimal waste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If building elements are custom-made to fit exact dimensions, then manufacturing precision is improved, but loss of time increases due to measurements and adaptations

Engineering Contradiction:

Improvedimensional accuracyVSAvoidinstallation time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The panel elements are pre-manufactured with standardized dimensions and features (protrusions, recesses, rounded corners) before installation. This preliminary preparation eliminates the need for on-site measurements, cutting, and adaptations, allowing workers to simply assemble pre-fitted components for rapid installation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The building elements are divided into modular panel segments with standardized interfaces. Each panel is a self-contained unit with integrated corner formations and connection features, allowing independent manufacturing and quick assembly without requiring custom fabrication for each specific installation location.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If building elements are cut or adapted on-site, then adaptability is improved, but object-generated harmful factors increase due to dirt and debris

Engineering Contradiction:

Improvedimensional adaptabilityVSAvoidconstruction debris

Core Design Contradiction:

Adaptability or versatilityVSObject-generated harmful factors

Solution Approach 1:

All necessary adaptations, including corner formations and dimensional adjustments, are performed during manufacturing before delivery to the construction site. Panels arrive ready-to-install with pre-formed features, eliminating on-site cutting operations that generate wood chips, gypsum dust, and metal flakes.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The panels are manufactured with rounded corners and smooth edges as standard features, eliminating the need for on-site cutting or filing that would generate harmful debris. The design inherently accommodates dimensional variations through the rounded corner geometry rather than requiring material removal.

Inventive Principle:

Principle #32Color changes

3Ease of manufacture

If incisions are made in panels for corner formation, then ease of manufacture is improved, but reliability worsens due to sensitivity to position variations

Engineering Contradiction:

Improvecorner formationVSAvoidcorner connection stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The corners are formed with rounded geometry rather than sharp incisions or joints. This curved corner design is inherently tolerant of positional variations in the panel elements, as the rounded shape can accommodate small misalignments without creating gaps or compromising the structural integrity of the corner connection.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The rounded corner design serves multiple functions simultaneously: it provides structural strength, accommodates dimensional variations, enables easy assembly, and creates a clean aesthetic appearance. This universal design approach eliminates the need for precise incision positioning while maintaining reliability across different installation scenarios.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Strength

If framed structures are used for walls and ceilings, then strength is improved, but device complexity increases due to multiple components

Engineering Contradiction:

Improvestructural strengthVSAvoidconstruction assembly

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The panel elements integrate multiple functions into single components: each panel serves as both a structural element and a finishing surface, with built-in corner formations and connection features. This merging of functions eliminates the need for separate framing members, corner pieces, and finishing materials, reducing overall assembly complexity while maintaining structural strength.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP3721026B1Improved construction panel

Publication Date: 2023.08.02 V FOLD GRP BVBA

Figure 1A~1B
Figure 2A~2B
Figure 2C~2D

AI summary

The current invention relates to a kit for a composite construction element, the kit comprising a set of substantially planar, interconnectable panel elements, each interconnectable panel element comprising a structural layer at least partially, and preferably completely, periodically provided with a set of protrusions and recesses at a first profile side, the protrusions and recesses being elongated along an x-direction within the plane of the panel element and the protrusions and recesses forming a periodic pattern in a y-direction within the plane of the panel element and perpendicular to the x-direction, preferably whereby the set of protrusions and recesses of two planar panel elements are configured to fit into one another.