Interlocking Modular Wall Panels for Rapid Construction
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Solution Overview
Problem
Temporary walls or partitions used in construction sites are costly, time-consuming to install, and difficult to reuse due to traditional building materials like lumber and drywall, which also generate debris.
Innovation Solution
A modular wall panel system featuring interlocking panels with a base track and elongated vertical extrusions, connection members, and skins that can be easily assembled and disassembled, allowing for a reusable and recyclable solution with a smooth, continuous surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional building materials like lumber and drywall are used to construct temporary walls, then the walls provide safety and security barriers, but the installation is costly, time-consuming, and creates debris
Solution Approach 1:
The wall system is divided into modular panels that can be independently manufactured and assembled. Each panel is a self-contained unit with standardized connection mechanisms, allowing rapid installation without custom fitting. The panels can be segmented into manageable sizes for easy handling and quick assembly on-site.
Solution Approach 2:
Connection members serve as intermediary elements that join panel components together. These standardized connectors facilitate rapid assembly by providing a simple interface between panels, eliminating the need for traditional fastening methods that require significant time and skill.
2Reliability
If traditional building materials like lumber and drywall are used to construct temporary walls, then the walls provide safety and security barriers, but the installation is costly and creates debris
Solution Approach 1:
The wall system is divided into modular panels that can be independently manufactured and assembled. Each panel is a self-contained unit with standardized connection mechanisms, allowing rapid installation without custom fitting. The panels can be segmented into manageable sizes for easy handling and quick assembly on-site.
Solution Approach 2:
The invention changes the material parameters from traditional lumber and drywall to alternative materials that can be engineered for specific performance characteristics. This includes using materials with optimized strength-to-weight ratios, dimensional stability, and ease of assembly, thereby eliminating debris generation during installation.
3Reliability
If traditional building materials like lumber and drywall are used to construct temporary walls, then the walls provide safety and security barriers, but the walls are difficult to reuse after no longer being needed
Solution Approach 1:
The wall system is divided into modular panels that can be independently manufactured and assembled. Each panel is a self-contained unit with standardized connection mechanisms, allowing rapid installation without custom fitting. The panels can be segmented into manageable sizes for easy handling and quick assembly on-site.
Solution Approach 2:
The panels are designed with universal connection interfaces that can be used in various configurations and locations. The standardized dimensions and connection mechanisms allow the same panel design to be reused across different projects and applications, maximizing versatility and reusability.
4Loss of time
If interlocking wall panels with connection members are used, then installation time is reduced and reusability is improved, but the panel structure becomes more complex
Solution Approach 1:
Multiple functions are merged into single components. The connection members integrate joining, alignment, and stabilization functions into a single element. The panel design combines structural support, surface finish, and connection interfaces into integrated components, reducing the total number of parts while simplifying assembly.
Solution Approach 2:
The connection members are designed to self-align and self-lock during assembly, eliminating the need for precise manual positioning or additional adjustment steps. The interlocking mechanism automatically ensures proper alignment and secure connection, reducing installation complexity despite the sophisticated underlying structure.
Data Source
AI summary
A wall panel system includes a base track and a plurality of interlocking wall panels. Each wall panel includes a continuous and unitarily formed first panel member and a continuous and unitarily formed second panel member. Each panel member includes a first face portion, an edge portion, and a plurality of connection members. The first and second panel members are interconnected by the plurality of connection member on the first panel member engaging the plurality of connection members on the second panel member.