Interlocking Panel System with Concealed Fasteners
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Solution Overview
Problem
Existing simulated building materials struggle to maintain the aesthetic illusion of natural materials like stone or brick due to visible attachment sites, and they lack the stability and strength needed, especially in high wind conditions.
Innovation Solution
The use of interlocking panels with modified tongue and groove joints, where the upper and lower interlocking members form a 45-degree angle, pressing the panels against the wall for secure attachment, and the incorporation of a screw attachment strip to hide fasteners, along with a textured and colored design to mimic natural materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If panels are attached to a wall using screws or nails, then the panels can be securely fastened to the building surface, but the attachment sites become visible and destroy the aesthetic illusion of simulated building materials
Solution Approach 1:
The patent extracts the fastening function from the visible panel surface by providing attachment means on the rear surface of the panel. The fasteners are inserted through the panel from the rear, allowing secure attachment to the building surface while keeping the front surface aesthetically pleasing without visible attachment sites.
Solution Approach 2:
The patent introduces an intermediary attachment mechanism consisting of attachment means on the rear surface and corresponding receptacles in the building surface. This intermediary system transfers the fastening function away from the visible front surface, allowing the panel to maintain its aesthetic appearance while still achieving secure attachment.
2Ease of manufacture
If traditional attachment methods are used, then fasteners can be inserted easily, but the panels lack stability and strength in high wind conditions
Solution Approach 1:
The patent applies local quality by concentrating the attachment function at specific localized points on the rear surface of the panel. The attachment means are positioned at strategic locations to provide optimal structural support and resistance to wind loads, rather than distributing attachment points across the entire panel surface.
Solution Approach 2:
The patent incorporates attachment means and receptacles as integral parts of the panel structure during manufacturing. This preliminary integration ensures that the attachment mechanism is pre-positioned and pre-configured for optimal structural performance, eliminating the need for field modifications and ensuring consistent attachment quality.
3Productivity
If panels are made from composite materials to simulate natural building materials, then cost and ease of work are improved, but the appearance may be considered aesthetically inferior
Solution Approach 1:
The patent employs color changes and surface treatments on the front surface of the panel to simulate the appearance of natural building materials. The composite panel is designed with appropriate coloring, texturing, and surface characteristics that visually replicate stone, brick, or other natural materials, making the synthetic appearance indistinguishable from natural counterparts.
Solution Approach 2:
The patent utilizes composite materials that combine synthetic components to achieve both aesthetic appearance and structural performance. The composite construction allows integration of attachment means within the material structure itself, providing both the visual qualities of natural materials and the functional advantages of synthetic composites.
Data Source
AI summary
The present disclosure concerns a system, methods and compositions for attaching architectural panels to a building surface, such as a wall. In certain embodiments, the system comprises panels, each with upper, lower and side interlocking members. In a preferred embodiment, the upper and lower interlocking members form a modified tongue and groove joint, with a 45 degree angle interface, while the side interlocking members form a ship lap joint. The upper and lower interlocking members may be designed to press the panels against the building surface and to hide the locations of screws or other attachment devices when the interlocking members are engaged. The system provides a stronger and more secure attachment of panels to a building surface, while eliminating the problem of having to disguise the location of the attachment devices where such devices are inserted directly through the surface of the panel.