Panel Assembly with Hidden Interlocking Mechanisms
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional panel assemblies are limited by their inability to provide desired aesthetic appeal, secure fabrication, on-site adjustments, contaminant-resistive properties, and are prone to waste, structural deficiencies, and difficulties in installation due to weight and size.
Innovation Solution
The use of extruded aluminum panel beams with hidden interconnecting mechanisms, such as flanges and clip members, allows for adjustable and aesthetically appealing panel assemblies that can be cut and assembled on-site, reducing waste and improving structural integrity and ease of installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional panel assemblies are made from wood or traditional materials and connected with adhesive on-site, then they can provide structural support and aesthetic appeal, but they become immobile without significant damage to the building or individual panel beams, and require caustic chemicals for finishing
Solution Approach 1:
The panel assembly is divided into multiple individual panel beams that can be separately handled, transported, and installed. Each panel beam is a discrete unit that can be independently manipulated, allowing for easy reconfiguration and removal without damaging the building or other panels. The beams connect through interlocking mechanisms rather than permanent adhesive bonds.
Solution Approach 2:
The patent replaces chemical adhesive bonding with a mechanical interlocking system. Panel beams feature receiving ends and inserting ends with complementary geometric profiles that mechanically engage with each other and with mounting structures, eliminating the need for caustic chemicals and enabling easy assembly and disassembly through mechanical means alone.
2Adaptability or versatility
If panel assemblies are cut to various dimensions to fit specific spaces, then they can accommodate different architectural requirements, but exposed cuts create aesthetic deficiencies and gaps that expand over time
Solution Approach 1:
Panel beams are pre-fabricated with standardized lengths and features before installation. The interlocking mechanisms are pre-formed on each beam, allowing for clean cuts at standardized intervals without exposing raw edges. End caps or covering features are attached beforehand to protect cut surfaces and maintain aesthetic appearance.
Solution Approach 2:
The patent introduces intermediary components such as end caps, cover strips, or finishing elements that mediate between the cut panel beams and the visible surface. These intermediaries conceal any cut surfaces, prevent gap formation, and maintain the aesthetic integrity of the assembly while allowing dimensional adaptation.
3Reliability
If panel assemblies are made as large single pieces to reduce the number of connections, then they can minimize potential connection points for failure, but they become heavy and difficult to hoist and install
Solution Approach 1:
The assembly is segmented into multiple manageable panel beams of standardized sizes that are lightweight enough for easy handling and installation. Despite the segmentation, reliability is maintained through robust interlocking mechanisms and multiple connection points distributed throughout the assembly, creating redundancy that compensates for the divided structure.
Solution Approach 2:
Different regions of the panel beam are designed with different properties: the connection regions feature reinforced interlocking mechanisms and mounting features for high strength, while the visible surface regions use lighter materials or thinner profiles for aesthetic appearance and reduced weight. This localized differentiation optimizes both reliability and handling ease.
4Shape
If panel assemblies are made of wood or susceptible materials to achieve aesthetic appeal, then they can provide warm appearance and traditional look, but they become vulnerable to mold, mildew, bacteria, odors, and other contaminants
Solution Approach 1:
The patent employs composite construction where panel beams are made from aluminum or other contaminant-resistant base materials, combined with aesthetic surface treatments such as anodizing, powder coating, or laminated veneers. This composite approach provides both the desired aesthetic appearance and inherent resistance to mold, mildew, bacteria, and odors, as the core material does not support biological growth.
Solution Approach 2:
The physical and chemical parameters of the panel surface are modified through surface treatments like anodizing or powder coating. These treatments change the surface properties to be non-porous and chemically resistant, preventing contaminant adhesion and growth while maintaining or enhancing the aesthetic appearance. The surface parameters are altered to achieve both beauty and contaminant resistance.
Data Source
AI summary
An end cap for a panel support of a panel assembly comprising an exposed surface and a side surface. The exposed surface of the end cap has opposing edges, and the exposed surface forms a selected end effect. The side surface has at least one fastener hole. The edges of the exposed surface of the end cap are configured to mate with an end surface of the panel support.