Simulated Masonry Panel Interlock for Gap Control
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Solution Overview
Problem
Existing synthetic wall coverings with simulated hand-laid masonry patterns face challenges in concealing panel-to-panel identity, achieving precise gap control, and replicating natural mortar lines, leading to unsightly gaps and unnatural appearances.
Innovation Solution
The use of thermoplastic panels with interlock arrangements, including hooks and slots, and undulating mortar lines, along with a textured surface finish, to ensure precise alignment and robust interlocking of panels, while avoiding thin tooling issues and enhancing aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thin tooling is used to form the flange receiving slot during injection molding, then the slot can be formed, but the tooling is subject to warpage or breakage causing variances in slot formation that impede precise panel interengagement
Solution Approach 1:
The patent changes the physical parameters of the tooling by increasing its thickness and structural rigidity. The flange receiving slot is formed using substantially planar tooling that is sufficiently thick to resist warpage and breakage during injection molding, while still producing the required slot geometry for panel interengagement.
2Productivity
If panels are identically molded to simplify production, then manufacturing efficiency is improved, but panel-to-panel identity becomes noticeable creating an unsightly appearance
Solution Approach 1:
The patent applies local quality by maintaining identical molded panels for manufacturing efficiency, but introducing visual variation through the staggered masonry pattern design. The simulated stone or brick rows are offset between adjacent panels, creating the appearance of hand-laid masonry while using standardized molded components.
Solution Approach 2:
The patent employs asymmetry in the staggered arrangement of simulated masonry rows between adjacent panels. The offset pattern creates visual interest and mimics natural stone or brick laying, preventing the panel-to-panel identity from being noticeable while maintaining production efficiency.
3Length of stationary object
If the flange receiving slot is formed with thin tooling, then the slot depth can be sufficient, but the tooling warpage or breakage causes unslightly and unnatural gaps between simulated masonry of adjacent panels
Solution Approach 1:
The patent changes the tooling parameter of thickness to eliminate warpage and breakage issues. The substantially planar tooling is made sufficiently thick to maintain dimensional stability during injection molding, ensuring consistent slot formation and uniform gaps between simulated masonry elements of adjacent panels.
4Shape
If simulated hand-laid stone or brick are separated by simulated mortar lines, then the masonry appearance is enhanced, but irregular or inconsistent gaps at adjoining panel ends that are not consistent with mortar lines are particularly noticeable
Solution Approach 1:
The patent uses precisely controlled tooling to form uniform gaps between simulated masonry elements at panel edges, ensuring these gaps are consistent with the mortar line spacing throughout the panel. This creates a uniform appearance that enhances the hand-laid masonry effect without noticeable irregularities.
Data Source
AI summary
A wall covering comprising a plurality of panels each formed with a plurality of horizontal rows of simulated building elements, such as hand laid stone separated by simulated lines of mortar. The panels have side marginal edge regions formed with hooks and side opening slots that are interengageable as an incident to relative lateral movement of the side marginal edge regions during installation, with the rows of simulated building elements in one panel, being drawn into aligned and predetermined spaced relation to the rows of building elements and adjacently mounted panel. The underlying side marginal edge region of each panel is formed with a non-planar undulating surface similar to the mortar lines throughout the panel, and the overlying side marginal edge region of each panel further is formed with a complementary undulating surface for tight mounted positioning onto the undulating surface of the underlying side marginal edge region.