Segmented Composite Panel False Joints
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Solution Overview
Problem
The existing manufacturing process for composite architectural panels with false joints is cumbersome and costly, involving multiple steps and leading to quality issues due to panel length variations and the use of separate facer elements.
Innovation Solution
The process simplifies the formation of false joints by using a continuous facer element bonded to a core material, allowing false joints to be formed at any position along the panel, enabling various aesthetic designs and reducing the length of facer sheets between joints, with pre-notched and roll-formed facer sheets to create U-shaped false joints for structural rigidity and aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If separate facer elements are used to form false joints, then the appearance of shorter panels is achieved, but the manufacturing process becomes cumbersome and costly
Solution Approach 1:
The patent merges multiple separate facer elements into a single continuous facer element that spans across the entire panel length. This continuous element is then folded back at specific locations to create false joint appearances, eliminating the need for multiple separate elements and their associated complex joining mechanisms while maintaining the desired aesthetic effect.
Solution Approach 2:
The continuous facer element is segmented through folding at specific locations to create the appearance of separate panel sections. The folds create visual breaks that mimic traditional panel joints while the underlying continuous structure simplifies manufacturing by eliminating actual joint assemblies.
2Shape
If separate facer elements are used for false joints, then aesthetic design is achieved, but quality issues arise due to panel length variations
Solution Approach 1:
By combining all facer elements into one continuous piece, the patent eliminates cumulative length variations that occur when assembling multiple separate elements. The continuous element ensures consistent panel length while the folding process creates the desired aesthetic joints without compromising dimensional precision.
3Shape
If separate facer elements are used to form false joints, then the appearance of shorter panels is achieved, but installation costs increase
Solution Approach 1:
The patent reduces installation complexity by using a single continuous facer element instead of multiple separate elements that require precise alignment and joining. This simplifies both the manufacturing process and field installation, thereby reducing overall installation costs while maintaining the aesthetic appearance of traditional panel joints.
4Productivity
If a continuous facer element is used, then manufacturing efficiency is enhanced, but the appearance of separate panels must be created through folding
Solution Approach 1:
The patent introduces dynamic folding structures into the continuous facer element. These folds are strategically positioned to create the appearance of separate panels while maintaining the continuous nature of the underlying structure. The folding mechanism provides a simple yet effective way to achieve complex visual effects without compromising manufacturing efficiency.
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 approach reduces installation costs, enhances manufacturing efficiency, and allows for various aesthetic designs such as a masonry brick appearance, while maintaining structural integrity and thermal efficiency, by forming continuous panels that mimic the appearance of shorter panels without the need for separate facer elements.
Implementation Method 1
a facer sheet 34 bonded to a core material 36
Data Source
AI summary
A building panel includes a facer sheet having opposed side joints, a liner sheet, a core material bonded between the facer and liner sheets, and at least one false joint formed in the facer sheet extending between the side joints such that the facer sheet is a continuous sheet across the at least one false joint. The at least one false joint includes a base surface extending into the foam core, opposing side surfaces connecting the base surface to the facer sheet, and a tab formed on each opposing side surface at one of the side joints. The tabs are folded under the one side joint.