Prefabricated Sandwich Wall Panels With Groove Spring Positioning
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Solution Overview
Problem
Conventional wall constructions for sports and acoustic applications are expensive, complex, and have unreliable panel positioning due to their multi-layered structures, leading to increased assembly effort and higher construction heights.
Innovation Solution
A prefabricated wall construction with sandwich panels featuring a hard, tough upper layer and a softer damping layer, where the upper layer includes groove/spring-like connecting means for precise panel positioning and reduced fastener usage, allowing for simpler and more stable assembly with lower heights.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional multi-layered baffle structures are used, then damping and insulation functions are achieved, but the construction height increases to at least 60mm and assembly becomes expensive and complex
Solution Approach 1:
The patent combines the damping layer and upper layer into a single integrated panel structure where the layers are factory-connected. This merging eliminates the need for separate assembly of multiple components, reducing construction height while maintaining the damping function through the integrated multi-layer design.
Solution Approach 2:
The damping layer and upper layer are pre-connected at the factory to form complete panels before delivery to the construction site. This preliminary assembly eliminates on-site layer-by-layer construction, reducing both construction height and assembly complexity while ensuring proper layer integration for damping performance.
2Ease of manufacture
If groove/spring-like connecting means are provided on the softer damping layer, then panel connection is possible, but positioning accuracy is unreliable due to material properties
Solution Approach 1:
The patent applies groove/spring-like connecting means specifically on the harder upper layer rather than the softer damping layer. The harder material provides superior dimensional stability and positioning accuracy, while the softer damping layer retains its cushioning properties. This localized application of connection features on the appropriate layer resolves the positioning accuracy issue.
3Strength
If individual wall panels are mounted via screws to a wall surface, then secure attachment is achieved, but the positioning and even-surface alignment requires significant effort
Solution Approach 1:
The groove/spring-like connecting means on the upper layer enable panels to self-align and position themselves relative to adjacent panels during assembly. The spring mechanism provides automatic positioning guidance, eliminating the need for manual alignment efforts while maintaining secure attachment through the interlocking groove-spring connection.
4Reliability
If complex multi-layered structures with separate components are used, then damping and insulation functions are achieved, but assembly effort and time increase significantly
Solution Approach 1:
The damping layer and upper layer are pre-assembled into integrated panels at the factory before delivery. This preliminary action completes the complex multi-layer construction off-site, allowing rapid on-site installation of complete panels rather than assembling layers sequentially during construction, thereby significantly increasing assembly productivity.
Solution Approach 2:
The patent merges the damping layer and upper layer into a single factory-integrated panel unit. This combination transforms a complex multi-step assembly process into a simple panel installation process, dramatically improving assembly speed while preserving the functional benefits of the multi-layer construction.
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
This solution enables accurate and efficient assembly of wall panels with reduced effort and lower construction heights, improving stability and acoustics while maintaining a high-quality appearance and ease of maintenance.
Implementation Method 1
groove / spring-like connecting means, which cooperate in such a way that adjacent wall panels in a direction perpendicular to a large surface of the wall panels are positioned together
Data Source
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AI summary
The invention relates to a wall construction and a method for mounting such a wall construction, wherein wall panels are designed as prefabricated sandwich structures.