Prefabricated Wall Panel Tongue and Groove Mounting

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Solution Overview

Problem

Prefabricated wall panels face challenges in durability and handling during installation, with existing designs prone to breakage and complex installation processes.

Innovation Solution

Incorporating a mounting element with a protrusion and keying holes, and a tongue and groove system for interlocking panels, made from materials like metal, plastic, or concrete, to enhance durability and simplify installation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If prefabricated wall panels are made from reinforced materials to improve durability, then resistance to damage during handling is improved, but weight increases making handling more difficult

Engineering Contradiction:

ImprovedurabilityVSAvoidweight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The wall panel is divided into modular sections with standardized dimensions, allowing larger panels to be broken down into manageable units that are easier to handle while maintaining overall structural integrity and durability through reinforced material construction

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Lifting inserts or integrated handling features are incorporated into the panel design to serve as intermediaries between the heavy reinforced panels and handling equipment, distributing the weight and enabling safer, more efficient handling of durable panels

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If complex mounting systems are used to improve panel interconnection strength, then joint strength is improved, but installation complexity increases

Engineering Contradiction:

Improvejoint strengthVSAvoidinstallation complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

Multiple functions (mounting, alignment, and interconnection) are merged into integrated tongue and groove features that are built into the panel edges themselves, eliminating the need for separate mounting hardware while achieving strong, reliable joints through simplified installation procedures

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If traditional installation methods are used to ensure proper panel alignment, then alignment precision is maintained, but installation time increases

Engineering Contradiction:

Improvealignment precisionVSAvoidinstallation time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

Alignment features such as guide edges, positioning ribs, and keyed interfaces are pre-formed during panel manufacturing, so that when panels are installed they automatically self-align without requiring manual measurement or adjustment, maintaining high alignment precision while dramatically reducing installation time

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11891814B2Prefabricated wall panel with tongue and groove construction

Publication Date: 2024.02.06 WESTLAKE ROYAL STONE LLC

AI summary

A prefabricated wall panel has a precast body including at least one decorative design element. In addition, the wall panel includes a mounting element having a first end embedded in the precast body and a second end projecting from the precast body. A groove is formed between the precast body and the second end of the mounting element along a first edge of the precast body. A tongue is formed along a second edge of the precast body opposite the first edge. The tongue and groove cooperate to allow prefabricated wall panels to be more easily installed on a support substrate.