Profiled Panel Assembly with Adjustable Edge Members
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Solution Overview
Problem
In the construction of tilt-up wall panels, existing technologies face challenges in maintaining dimensional control and flexibility due to hydrostatic forces during cementitious material casting, especially on-site, and in simplifying the installation of fixtures like windows and doors, which are hindered by the need for precise standardization of panel dimensions and shapes.
Innovation Solution
A panel assembly comprising a deck with a peripheral edge formed from sheet metal, incorporating stiffening formations and adjustable edge members that can accommodate hydrostatic forces and allow for flexible panel dimensions, featuring interlocking profiles for fixtures, and embedded edge members to maintain structural integrity and simplify fixture installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If standard width profiled sheets are assembled in overlapping side by side configuration, then manufacturing standardization is improved, but flexibility in panel dimensions is worsened
Solution Approach 1:
The edge member is designed with adjustable positioning capabilities, allowing it to be moved along the deck to accommodate different panel dimensions. This dynamic adjustment feature enables the same standardized edge member to adapt to various panel sizes while maintaining manufacturing standardization of the component itself.
Solution Approach 2:
The panel assembly is divided into modular components including the deck, edge member, and cavity structure. This segmentation allows the edge member to be standardized while the overall panel dimensions are adjusted by varying the deck size or positioning, achieving both standardization and flexibility.
2Adaptability or versatility
If panels are cast on-site, then construction flexibility is improved, but dimensional control is worsened due to inadequate jigs for containing hydrostatic forces
Solution Approach 1:
The peripheral edge is designed with a curved or rounded profile that naturally resists hydrostatic forces during casting. This curved geometry distributes the hydrostatic pressure more effectively compared to sharp corners, maintaining dimensional control during on-site casting operations.
Solution Approach 2:
The edge member is pre-formed with integrated stiffening formations and curved profiles before assembly. This preliminary shaping provides inherent resistance to hydrostatic forces, eliminating the need for additional on-site jigs or supports while maintaining dimensional precision during casting.
3Ease of operation
If fixtures are installed after wall panels are in place, then installation simplicity is improved, but construction time is worsened
Solution Approach 1:
The edge member is pre-formed with integrated rebates and receiving features for fixtures during the panel manufacturing process. This allows fixtures to be pre-positioned within the panel assembly before installation, enabling simultaneous completion of panel and fixture installation rather than sequential installation, thereby reducing construction time while maintaining simplicity.
4Strength
If stiffening formations are added to the deck, then structural strength is improved, but dimensional control during casting is worsened if they deform significantly
Solution Approach 1:
The stiffening formations are designed with optimized geometric parameters including sufficient thickness and strategic positioning to provide structural strength while maintaining rigidity. The formations are engineered to minimize deformation under hydrostatic loading, balancing strength enhancement with dimensional control during the casting process.
Data Source
AI summary
A profiled panel (10) is disclosed. The profiled panel (10) is formed from sheet material. The panel (10) has a plurality of fixed longitudinally extending formations (12) that provide one or more base characteristics of the panel (10), and at least one variable longitudinal formation (22). The variable longitudinal formations (22) are arranged to vary from one panel to another panel. This enables the variance of a width dimension (28) of the panel (10). A profiled panel is also disclosed that includes at least one edge member which is profiled to receive and/or form part of said wall fixture.