Modular Wall Panel Fabrication with Integrated Openings
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Solution Overview
Problem
Conventional methods for producing three-dimensional building structures using solid wood or wood-based materials result in significant material waste due to the need for sawing out full-surface elements for door and window openings, leading to inefficient material consumption.
Innovation Solution
The method involves subdividing the structure into panel planes, segmenting them into sections oriented in longitudinal or transverse directions, and cutting these sections from a continuous material strand to create flat openings, allowing for efficient assembly and connection of prefabricated panel sections with varying materials and joint designs, reducing material waste by avoiding sawing for openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If full-surface wall or ceiling elements are produced and then sawn to create door and window openings, then continuous planar surfaces can be achieved, but significant material waste occurs
Solution Approach 1:
The wall or ceiling elements are segmented into modular sections with integrated openings before assembly. Instead of creating continuous full-surface elements and then cutting openings, the patent divides the structure into discrete modules (e.g., wall sections with window openings, door openings) that are pre-fabricated and then assembled together. This segmentation allows openings to be built-in from the start rather than cut out later, eliminating the material waste associated with sawing out openings from continuous surfaces.
2Ease of manufacture
If openings are created by sawing out full-surface elements, then simple manufacturing process can be maintained, but material consumption increases significantly
Solution Approach 1:
The openings are incorporated into the modular sections during the pre-fabrication stage rather than being created after assembly. Wall sections with window and door openings are manufactured as complete modules in advance, with all necessary cutouts and structural elements already in place. This preliminary action eliminates the need for on-site sawing operations and reduces material waste by ensuring precise material usage during controlled factory manufacturing.
Solution Approach 2:
The patent transitions from a two-dimensional approach (continuous surfaces with cutout openings) to a three-dimensional modular approach where openings are integrated into the volume and structure of pre-fabricated sections. Instead of flattening the problem to a 2D surface and cutting holes, the solution builds openings as inherent features of 3D modular components that include framing, insulation, and finishing elements, thereby reducing material waste while maintaining manufacturing simplicity.
3Ease of operation
If modular wall panels are connected via rebate and groove connections, then assembly can be simplified, but material waste problem persists when openings are needed
Solution Approach 1:
The patent merges the modular panel connection system with integrated openings by combining multiple functions into single wall sections. Instead of separate panels connected by rebates and grooves that still require post-assembly cutting for openings, the solution integrates the opening structures directly into the modular sections themselves. This merging allows the connection system and opening structures to work together as unified components, maintaining easy assembly while eliminating material waste from creating openings in pre-assembled continuous surfaces.
Data Source
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AI summary
The invention relates to a method for producing a three-dimensional structure (1), which is produced substantially from plate-shaped material blanks, which material blanks are cut to size in portions from at least one material strand and then connected to one another in the form of the structure (1). The method according to the invention is distinguished by its material-saving use of the materials or building materials used.