Modular Wall Systems With Non-Progressive Installation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing modular wall systems in hygienic environments face alignment issues during installation, leading to installation delays, increased costs, and compromised hygiene due to gaps and protrusions, which complicate maintenance and hinder aesthetics.
Innovation Solution
A modular wall system with backplates and non-progressive installation methods, featuring interleaving flanges and fastener openings, allows for easy alignment and gap coverage, maintaining structural integrity and hygiene.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wall panels are installed using progressive installation method starting from a corner, then the wall system can be assembled, but installation becomes complicated, expensive, and time-delayed
Solution Approach 1:
The patent inverts the traditional progressive installation approach by enabling non-progressive installation where panels can be installed in any sequence rather than requiring corner-to-corner progression. This is achieved through the backplate-stud framework that provides independent attachment points for each panel, eliminating the need for sequential assembly and allowing parallel installation operations.
Solution Approach 2:
The wall system is segmented into independent modular panels that can be installed separately on individual backplates. Each panel-backplate-stud assembly functions as an independent unit, allowing installation teams to work on multiple sections simultaneously without interfering with each other, thereby increasing productivity and reducing installation time.
2Ease of repair
If wall panels are installed progressively from a corner, then the wall system can be assembled, but individual panel removal becomes difficult and expensive
Solution Approach 1:
Each wall panel is segmented as an independent module attached to its own backplate and stud assembly. This segmentation allows any individual panel to be removed without affecting adjacent panels, facilitating easy maintenance, repair, or reconfiguration. The modular design enables panel removal and replacement without requiring disassembly of the entire wall system.
Solution Approach 2:
The connection system provides dynamic adjustability through the backplate-stud framework, allowing panels to be easily attached and detached. The fastening mechanism enables reversible connections that can be opened and closed multiple times, supporting frequent maintenance operations and flexible reconfiguration without increasing overall system complexity.
3Productivity
If wall panels do not align with studs during installation, then installation flexibility is maintained, but re-forming of panels is required causing delays and increased costs
Solution Approach 1:
The backplate-stud framework provides self-aligning features that guide panel installation. The backplates are pre-positioned on studs with alignment features that automatically accommodate panel placement, eliminating the need for precise pre-alignment between panels and studs. This self-service alignment mechanism reduces installation errors and rework.
Solution Approach 2:
The system incorporates adjustable parameters in the backplate-stud connection that allow accommodation of dimensional variations. The fastening mechanism can adjust to slight misalignments through variable positioning, allowing panels to be installed even when perfect alignment with studs is not achieved, thereby maintaining installation efficiency without requiring panel re-forming.
4Object-affected harmful factors
If gaps occur in the wall system between panels or near edges, then installation simplicity is maintained, but hygiene is compromised and aesthetics are hindered
Solution Approach 1:
The backplate-stud framework acts as an intermediary structure that provides a continuous substrate behind the wall panels. This intermediary framework allows for the integration of sealing and gap-covering elements that are structurally supported by the backplates and studs, enabling effective hygiene sealing without adding significant complexity to the overall wall assembly.
Data Source
AI summary
Aspects of the present disclosure relate to modular wall systems and methods of installing modular wall systems in hygienic environments. In one aspect, gap cover apparatus are disclosed. In one aspect, backplate arrangements are disclosed. In one aspect, non-progressive installation methods are disclosed. The modular wall systems can eliminate protruding ledges while maintaining structural integrity and hygienic properties.