Interlocking Wall Panels for Modular Bathroom Pods

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Solution Overview

Problem

Existing methods for constructing and joining wall panels, particularly for forming interior corners, are time-consuming, labor-intensive, and prone to inaccuracies, requiring taping and mudding processes that significantly delay the completion of wall finishes.

Innovation Solution

The use of interlocking wall panels with male and female interlock members, precision-machined using computer-controlled routers, allows for quick and accurate assembly without the need for taping and mudding, enabling efficient construction of modular building units like bathroom pods.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If traditional taping and mudding methods are used to join wall panels and form corners, then the walls can be finished with a flush surface, but the process requires considerable time and labor

Engineering Contradiction:

Improveease of joining wall panelsVSAvoiddrying time and construction time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The wall panel is segmented into distinct components: a male interlock member with protruding tabs and a female interlock member with recessed slots. This segmentation allows the joining function to be separated from the panel surface, enabling mechanical interlocking without requiring taping and mudding processes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The interlock members are pre-formed and integrated into the wall panels during manufacturing. The male and female interlock features are precision-machined in advance, eliminating the need for on-site taping and mudding operations and reducing construction time significantly.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If traditional drywall and gypsum panel methods are used, then walls can be constructed and joined, but the process is labor-intensive and subject to inaccuracies

Engineering Contradiction:

Improveconstruction speedVSAvoidcomplexity of joining process

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The traditional mechanical process of taping and mudding is replaced with a precision machining system. Computer-controlled routers are used to machine the interlock members with high accuracy, eliminating manual labor and reducing inaccuracies associated with traditional methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If interlocking members are precision-machined using computer-controlled routers, then assembly accuracy is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveprecision of interlocking featuresVSAvoidease of machining interlock members

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The manufacturing process transitions from manual or less precise machining methods to computer-controlled routing. This parameter change in the manufacturing process enables high precision interlocking features while maintaining ease of manufacture through automated control and standardized procedures.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS10961702B2System and method of interlocking wall panels

Publication Date: 2021.03.30 SUREPODS LLC

AI summary

An interconnectable wall panel system and method of forming and assembling the same are provided. A plurality of wall panels are provided that are interconnectable in a predetermined manner and arrangement, and wherein the wall panels comprise features for enhancing ease and accuracy of assembly. Wall panel members of the present disclosure are suitable for use in constructing modular building units, such as bathroom pods.