Modular Wall Panel Tile Retention via Segmented Support
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Solution Overview
Problem
Existing modular wall panel systems face challenges in securely attaching heavy or expensive tiles, ensuring proper support to prevent damage or injury, and require configurations that can accommodate electrical and communication cables while being compact for shipping and adaptable to different office environments.
Innovation Solution
The modular wall panel system features a support frame with adjustable vertical posts and a lower sill with attachment notches, stiffener brackets with engagement tabs, and a top cap that retain tiles without supporting their weight, along with features like light-blocking attachments and raceway mounting brackets for cable management, allowing for customizable configurations and secure assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tiles are securely attached to the frame using traditional support methods, then tile security is improved, but the structural complexity and shipping space requirements increase
Solution Approach 1:
The tile support function is divided into two independent components: the lower sill supports the tile weight, while separate stiffener brackets with engagement tabs secure the tile to the frame. This segmentation allows each component to be optimized for its specific function and shipped separately in compact configurations.
Solution Approach 2:
The stiffener brackets are extracted as separate removable components from the main frame structure. These brackets can be attached to the tile back surface and engaged with the frame independently, reducing the overall structural complexity while maintaining secure tile attachment.
2Strength
If traditional tile support structures are used, then tile weight support is ensured, but shipping space and assembly complexity increase
Solution Approach 1:
The stiffener brackets are designed to nest within the tile structure during shipping, and can be easily attached when needed. The lower sill integrates with the frame structure, allowing components to be compact during transport but fully functional during installation.
Solution Approach 2:
The stiffener brackets with engagement tabs are designed to self-align and self-secure to the frame without requiring additional fasteners or complex assembly procedures. The tabs engage with corresponding slots in the frame, providing automatic positioning and secure attachment.
3Ease of manufacture
If the system is designed for fixed configurations, then manufacturing simplicity is improved, but adaptability to different office environments deteriorates
Solution Approach 1:
The system employs adjustable vertical posts with movable attachment notches that can be repositioned along the post length. This dynamic adjustment capability allows the same frame structure to accommodate tiles at different heights and positions, providing configurability while maintaining manufacturing simplicity through standardized components.
Solution Approach 2:
The lower sill and stiffener brackets are designed as universal components that can be used with any tile size or type in the system. The engagement tabs and attachment notches provide a standardized interface that works across different configurations, allowing a single set of components to serve multiple functions and adapt to various office environments.
Data Source
AI summary
A modular wall panel system including a series of wall panels connectable to each other. Each of the wall panels is formed from a support frame having a pair of spaced vertical posts and an upper header and a lower sill extending between the vertical posts. The lower sill is received within attachment notches formed in each of the vertical posts near the bottom end of each post. The attachment notches are spaced along the length of the vertical post such that the position of the sill can be adjusted. The lower sill includes a trim channel that receives the bottom of a tile mounted to the support frame. A top cap is attached to the header and engages a top end of the tile to aid in retaining the tile on the support frame. The tile may be a segmented tile having a lower portion and an upper portion joined to each other by a segmented trim channel. The segmented trim channel between the upper and lower portions is not connected to the support frame. Each panel can receive a stacking section to extend the height of the panel. The stacking section includes a pair of shortened vertical posts and a header. The stacking section is secured to the support frame through a pair of spaced blades. The lower edge of each panel can be elevated above the floor and the trim panel supported beneath the panels to create an enclosed raceway.