Modular Wall Panels With Interlocking Frame Components
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Solution Overview
Problem
Current modular wall systems are cumbersome, heavy, and difficult to assemble and disassemble, requiring tools and limiting customization and transportation ease, while lacking in structural soundness and aesthetic flexibility.
Innovation Solution
A modular wall system composed of lightweight, hollow wall panels with interlocking frame components that provide structural support, allowing for easy assembly and disassembly without tools, and enabling customizable configurations and aesthetics through interchangeable frame components and cap inserts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If modular wall panels are made of sheetrock or plywood, then structural strength is improved, but weight increases making them cumbersome to transport
Solution Approach 1:
The wall panel is divided into multiple hollow compartments separated by internal partitions. This segmentation reduces the overall weight of the panel while maintaining structural integrity through the distributed framework of partitions and external framing members.
Solution Approach 2:
The wall panel employs a hollow interior structure with multiple compartments that are essentially porous spaces. This porous configuration significantly reduces weight compared to solid sheetrock or plywood while providing adequate structural support through the remaining material framework.
2Weight of moving object
If wall panels are made lightweight and hollow, then ease of transport is improved, but structural soundness deteriorates
Solution Approach 1:
The hollow interior is segmented into multiple compartments by internal partitions. This segmentation creates a truss-like structure that provides structural rigidity and resistance to bending and twisting forces, compensating for the reduced material quantity.
Solution Approach 2:
The wall panel combines different materials including the hollow core structure, internal partitions, and external framing members to create a composite construction that achieves both lightweight properties and structural soundness through the synergistic arrangement of components.
3Stability of the object's composition
If wall panels use hinges or connection hardware, then structural stability is improved, but ease of assembly and disassembly deteriorates requiring tools
Solution Approach 1:
Traditional mechanical fastening systems like screws, bolts, and welds are replaced with a friction-based insertion system. The framing members feature complementary geometric profiles that engage through friction and geometric interlocking, eliminating the need for tools while maintaining structural stability.
Solution Approach 2:
The connection system is designed to be self-securing through friction and geometric interlocking. The framing members automatically stabilize each other upon insertion without requiring external fastening operations, making the assembly process tool-free while maintaining structural integrity.
4Ease of operation
If wall panels are designed for easy assembly without tools, then ease of operation is improved, but structural stability deteriorates
Solution Approach 1:
The framing members incorporate curved or rounded geometric profiles rather than sharp edges. This curvature design increases the surface area contact between connecting members, enhancing friction-based stability while maintaining easy tool-free assembly through the smooth geometric interfaces.
Solution Approach 2:
The framing members are pre-formed with complementary geometric profiles during manufacturing. This preliminary preparation of the connection interfaces ensures that when assembled, the members naturally engage with optimal friction and geometric interlocking, achieving structural stability without requiring additional fastening actions.
5Adaptability or versatility
If wall panels are made customizable with various configurations, then adaptability is improved, but device complexity increases
Solution Approach 1:
The framing members are designed with universal geometric profiles and connection interfaces that can be used in multiple configurations and orientations. This universality allows the same basic component to serve various functions in different wall arrangements, achieving high adaptability without increasing the variety of unique parts required.
Solution Approach 2:
The modular wall system employs dynamic configurability where the same set of standardized framing members can be dynamically rearranged into different configurations. This dynamic adaptability is achieved through the flexible combination rules of the geometric connection system rather than through multiple specialized components.
Data Source
AI summary
Modular wall panels having a frame of a plurality of frame components and at least one wall sheet affixed to the frame. Frame component may have angled ends, straight ends, or a combination thereof. Each end of the frame components may have at least one fastener or at least one corresponding receiver to selectively connect adjacent frame components end on end in forming a frame, including corners. Frames can thus be assembled in the field and are fully customizable. A hub may be utilized with multiple sides having fastener(s) or receiver(s) to interconnect frame components. A wall system includes a plurality of such wall panels connected to one another along the outer surfaces of the frame components of their respective frames.