Modular Wall Height Adjustment With Interlocking Wedge Members
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Solution Overview
Problem
Current modular wall systems face challenges in reusability, modularity, configurability, and on-site re-configurability due to on-site cutting and handling of structural components, leading to damage, increased costs, and specialized training requirements, which hinder the realization of their cost and time advantages.
Innovation Solution
A modular wall system with a panel receiver structure, vertical panels, and removably attachable fascia trim members, along with height adjustment devices using wedge members with interengaged teeth, allows for easy reconfiguration and concealment of structural elements, enhancing assembly efficiency and upgradeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If components are cut to size for particular positional placement to achieve clean appearance, then manufacturing precision is improved, but adaptability deteriorates
Solution Approach 1:
The wall system is divided into separate components: finished wall sections that maintain their factory-finished surfaces and structural components (tracks, studs, connectors) that are designed to be cut and assembled on-site. This segmentation allows each type of component to be optimized for its specific function without compromising the other.
Solution Approach 2:
The finished surfaces are extracted from the structural components and applied only to the visible wall sections. The structural components are designed with raw, cuttable surfaces while the wall sections maintain factory-applied finishes, separating the aesthetic function from the structural function.
2Reliability
If specialized training is provided for handling and assembly to prevent damage, then reliability is improved, but device complexity deteriorates
Solution Approach 1:
The system uses sacrificial protective elements such as foam edge protectors and cardboard corner guards that are inexpensive and easily replaceable. These protect the finished surfaces during handling and installation, and can be discarded after use without affecting the overall system cost significantly.
Solution Approach 2:
The design incorporates self-aligning features and tolerance-built connection points that guide improper installations back into correct positioning, reducing the need for highly skilled labor. The system is designed to be forgiving of installation variations while maintaining structural integrity.
3Adaptability or versatility
If components are designed as structural and finish elements to emulate finished walls, then adaptability is improved, but object-generated harmful factors worsen
Solution Approach 1:
The wall system separates structural components from finished components. Structural elements (metal tracks and studs) are designed to be cut and assembled on-site, while finished wall sections are factory-assembled with protective surfaces. This segmentation prevents damage to finished surfaces during on-site cutting and assembly operations.
Solution Approach 2:
All cutting, drilling, and structural assembly operations are performed on the structural components before the finished wall sections are installed. The finished sections are handled only for final installation, minimizing their exposure to damage risks during the construction process.
4Adaptability or versatility
If on-site cutting and adjustment is performed to fit varied ceiling heights and non-plumb walls, then adaptability is improved, but loss of time worsens
Solution Approach 1:
The system incorporates adjustable connection points and flexible mounting options that allow the wall sections to adapt to varying ceiling heights and wall plumbness without requiring precise pre-cutting. The structural framework can be adjusted on-site to accommodate building irregularities, reducing time spent on precise measurements and cutting.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables flexible and cost-effective reconfiguration of modular walls, reducing damage and training needs, while maintaining a clean, finished appearance, and allowing for easy upgrades and changes in look over time.
Implementation Method 1
The height adjustment device may include an upper wedge member having a plurality of teeth on a lower angled surface
Data Source
AI summary
A height adjustment device for adjusting a panel of a modular wall. The height adjustment device comprises an upper wedge member having a plurality of teeth on a lower angled surface thereof and a lower wedge member having a plurality of teeth on an upper angled surface thereof, the lower wedge member being positioned for supporting the upper wedge member. The upper wedge member is positioned for supporting the panel. The teeth on the upper and lower angled surfaces are interengaged with one another to prevent relative movement of the wedge members to fix a height of the panel. The teeth are disengageable to enable adjustment movement between the wedge members to vary the height of the panel.