Interlocking Decorative Panels for Moisture-Resistant Seamless Joints
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Solution Overview
Problem
Traditional building materials like ceramic tiles and planks are not moisture-resistant, leading to deformation and mildew, and wall panels lack interlocking mechanisms, resulting in larger seams that accumulate dust and pollutants, affecting aesthetics and health, especially in humid environments.
Innovation Solution
The development of panels with surface patterns or coating layers and interlocking mechanisms featuring a 'tongue/protrusion' and 'groove/recess' structure, allowing seamless jointing to prevent moisture and bacteria accumulation, while being cost-efficient and easy to install.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional ceramic tiles or planks are used for wall paneling, then the material is easy to obtain and install, but the panels are not moisture-resistant and deform over time
Solution Approach 1:
The patent uses WPC (wood-plastic composite) material that combines wood fibers with plastic polymers to create a composite panel that is both moisture-resistant and dimensionally stable. This composite structure prevents the deformation issues associated with traditional wood or ceramic materials while maintaining ease of installation.
2Ease of operation
If wall panels are designed with differentiated connection edges in shiplap style, then the panels are easy to assemble, but the seams among panels become larger over time and accumulate dust and pollutants
Solution Approach 1:
The patent combines the connection edges of adjacent panels to form a flush, seamless joint where the edges merge completely without gaps. This eliminates the shiplap-style seams that accumulate dust and pollutants, while the interlocking mechanism maintains ease of assembly by allowing panels to be clicked together.
Solution Approach 2:
The patent converts the potential harm of exposed seams into a benefit by designing an interlocking edge structure that eliminates gaps. The connection edges are shaped to interlock tightly, transforming the weakness of seam exposure into a strength of seamless integration that prevents contaminant accumulation.
3Ease of manufacture
If wall panels are installed without interlocking mechanisms, then the installation is simple, but the panels separate over time via in-plane displacement
Solution Approach 1:
The patent segments the connection edge into distinct interlocking components: a protrusion on one panel that fits into a recess on the adjacent panel. This segmented design provides mechanical interlocking for stability while maintaining installation simplicity through a click-together mechanism that requires no additional fasteners.
Data Source
AI summary
Disclosed is a panel comprising a substrate (1), wherein the outer surface of the substrate (1) is covered with a coating layer (8), wherein one edge of the substrate (1) is provided with a recess (3), and a groove (4) is arranged inside the substrate (1) adjacent and interconnected to the recess (4), and wherein the opposite edge of the substrate (1) is provided with a protrusion (7) that can be fitted into the recess (3), and a tongue (6) is extended from the protrusion (7) that can fitted into the groove (4). The substrate is made of 100 parts by mass of PVC resin or PVC powder, 25-45 parts of styrene elastomer, 180-280 parts of stone powder, sawdust or rock, 1-10 parts of an additive, and 1-4 parts of an elastomer coupling agent. Also disclosed is a decorative panel formed by arranging and interlocking the panels in sequence by fitting the protrusion of a panel into the recess of a neighboring panel, as well as a panel installation process.