Sloped Interlock Panels for Decorative Coverings
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Solution Overview
Problem
Existing panel interlocks for decorative coverings on support surfaces are difficult to manufacture and prone to damage due to protruding elements, leading to installation issues.
Innovation Solution
The system employs non-protruding interlocks with sloped abutting surfaces at the overlapping ends of panels, which are easily integrated during manufacturing and provide a secure connection without the risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If protruding interlock elements are used to secure adjacent panels, then panel stability is improved, but manufacturing difficulty and damage risk increase
Solution Approach 1:
Instead of using protruding elements that stick out from the panel surface, the patent inverts the approach by using recessed interlock features. The interlocks are formed as cavities or recesses within the panel body, allowing adjacent panels to engage without external protrusions. This inversion eliminates the manufacturing and damage issues associated with protruding elements while maintaining panel stability.
Solution Approach 2:
The interlock features are nested within the panel structure itself rather than extending outward. The recessed interlocks are integrated into the panel body, creating a compact design where the locking mechanism is contained within the panel's own geometry. This nesting approach allows for easier manufacturing and reduces the risk of damage during handling and installation.
2Stability of the object's composition
If protruding interlock elements are used to secure adjacent panels, then panel stability is improved, but damage risk during manufacturing and transportation increases
Solution Approach 1:
The patent eliminates the protruding nature of interlock elements by inverting the design to use recessed features. This inversion removes the vulnerability points that were previously exposed on the panel surface, thereby reducing the risk of damage during manufacturing, transportation, and installation while maintaining the structural stability provided by the interlocks.
Solution Approach 2:
The patent converts the potential harm of protruding elements (which cause damage) into a benefit by using recessed interlocks. The same interlocking function is achieved, but now the features are protected within the panel structure, transforming a vulnerable design into a durable one that resists damage during handling and installation.
3Stability of the object's composition
If complex interlock mechanisms are used to secure panels, then panel stability is improved, but installation complexity increases
Solution Approach 1:
The interlock mechanism is segmented into simple, discrete recessed features that can be easily formed during panel manufacturing. Rather than using complex mechanical assemblies, the patent divides the interlocking function into basic geometric recesses that align and engage automatically during installation, simplifying the installation process while maintaining panel stability.
Solution Approach 2:
The recessed interlock features are designed to self-align and self-engage during panel installation. The geometry of the recesses allows adjacent panels to automatically find their correct position and lock together without requiring complex alignment procedures or additional fastening operations, thereby simplifying installation while ensuring stable panel composition.
Data Source
AI summary
A system for decoratively covering a support surface is provided. The system comprises a plurality of panels. Each panel includes a top, a bottom, and first and second ends. Each panel includes a nailing hem for mounting the panel to the support surface. Each panel also includes first and second rows of decorative portions simulating building materials. A riser interconnects the first and second rows. Each panel further includes a flap extending from the riser at the first end and a catch extending from the riser at the second end. The flap and catch mate with a corresponding catch and flap of horizontally adjacent panels. The flap and catch are both sloped upwardly toward the top at an acute angle to provide a mating fit between corresponding flaps and catches.