Modular 3D Wall Frame with Telescopic Connectors
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Solution Overview
Problem
Existing wall panel systems require custom measurement and cutting of frames, with a fixed 90-degree configuration, limiting flexibility in panel fabrication and connection options, and lack a 'one-size-fits-all' solution for adjustable dimensions and non-orthogonal connections.
Innovation Solution
A method using corner castings with two- or three-legged cube connectors and linear extrusion members that can be telescopically connected to form a three-dimensional frame structure, allowing for adjustable dimensions and non-orthogonal connections, with panels secured using adhesives and gaskets for spacing and support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom measurement and cutting of frames is performed, then precise fit for specific dimensions is achieved, but construction time and complexity increase
Solution Approach 1:
The frame system is segmented into standardized modular components (corner castings with cube connectors and linear extrusion members) that can be assembled in different configurations without custom cutting, resolving the contradiction between precision fit and construction time
Solution Approach 2:
The system allows parameter changes in frame dimensions and angles through telescopic connection of modular components, enabling precise fit for various dimensions without requiring custom measurement and cutting on-site
2Ease of manufacture
If fixed 90-degree configuration is used, then manufacturing simplicity is maintained, but design flexibility and adaptability are limited
Solution Approach 1:
The frame structure transitions from fixed 90-degree configuration to a dynamic system with adjustable angles and dimensions through telescopic connection of modular components, maintaining manufacturing simplicity while enabling design flexibility
Solution Approach 2:
The modular components (corner castings and linear extrusion members) serve multiple functions - forming corners, straight edges, and various angles through different connection configurations, providing universal applicability for diverse panel arrangements
3Adaptability or versatility
If on-site cutting of frames is performed, then custom dimensions are achieved, but construction efficiency decreases
Solution Approach 1:
Frame components are pre-manufactured with standardized dimensions and connection features at the factory, eliminating the need for on-site cutting and significantly improving construction efficiency while maintaining dimensional adaptability through modular assembly
Solution Approach 2:
The system uses replicated modular components that can be assembled in various configurations to achieve custom dimensions without copying or modifying individual pieces on-site, maintaining both efficiency and adaptability
Data Source
AI summary
A method of forming a three-dimensional frame structure is provided. The structure includes a plurality of rigid wall panels that are adhesively secured to components of a system. The components are specially designed to allow for adjusting the dimensions of a wall panel. The method generally comprises providing a series of corner castings, and providing a series of linear extrusion members. The method also includes connecting the series of corner castings and the plurality of linear extrusion members to form a three-dimensional frame, and adhesively securing rigid wall panels to the three-dimensional frame to form the frame structure. The rigid panels may include porcelain ceramic tiles, natural stone tiles, or other panels.