Structural Panel Assembly with Vertical Locking Mechanism
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Solution Overview
Problem
Conventional wall construction techniques are time-consuming, labor-intensive, and require specialized tools and skills, while prefabricated components still face challenges with installation efficiency and quality consistency.
Innovation Solution
A structural panel assembly with a vertical locking mechanism and rigid insulating layers, allowing for easy assembly of building walls using minimal tools and skills, featuring a male and female member locking system and corner securement assemblies for efficient panel interlocking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional wall construction techniques are used, then structural integrity can be achieved, but construction time and labor requirements increase substantially
Solution Approach 1:
The locking mechanism components (male member, female member, locking tab) are pre-configured on the panels during manufacturing, allowing for rapid on-site assembly without requiring complex field fabrication or adjustment. The panels are prepared in advance with integrated locking features that enable quick interconnection.
Solution Approach 2:
The wall construction system is divided into discrete panels with standardized locking interfaces. Each panel is an independent module that can be assembled separately and then connected to form the complete wall structure, enabling parallel installation and reducing overall construction time.
2Ease of operation
If conventional wall construction techniques are used, then walls can be built, but field labor and specialized skills requirements increase
Solution Approach 1:
The locking mechanism is designed to be self-aligning and self-latching. The male member inserts into the female member, and the locking tab automatically engages with the locking slot, allowing workers to assemble the connection through simple insertion and rotation actions without requiring specialized training or tools.
Solution Approach 2:
The locking tab acts as an intermediary element that mediates the connection between panels. It provides a simple rotational motion interface that converts the insertion action into a locked position, eliminating the need for complex fastening operations or specialized tools.
3Productivity
If prefabricated components are used, then installation time can be reduced, but installation complexity and field labor requirements remain high
Solution Approach 1:
The locking mechanism integrates multiple functions into a single unified system. The male member, female member, and locking tab work together as an integrated assembly that provides both structural connection and locking functionality, eliminating the need for separate fasteners, washers, or adjustment mechanisms.
Solution Approach 2:
The locking mechanism is designed with universal applicability across different panel configurations. The standardized male-female locking interface can be used consistently throughout the wall construction, allowing the same assembly procedure to be repeated for various panel sizes and positions, reducing overall system complexity.
4Manufacturing precision
If standardized prefabricated components are used, then quality consistency can be improved, but installation time and labor requirements remain substantial
Solution Approach 1:
The locking mechanism components are precisely manufactured and pre-positioned on the panels during factory production. This preliminary action ensures that the male and female members are correctly aligned and sized, allowing for rapid on-site assembly without requiring field adjustments or complex alignment procedures.
Solution Approach 2:
The system replaces complex mechanical fastening operations with a simplified insertion and rotation mechanism. The standardized locking interface eliminates the need for multiple fasteners, welding, or specialized mechanical assemblies, reducing both installation time and the skill level required while maintaining manufacturing precision.
Data Source
AI summary
A structural panel having a structural inner core with a male member and a female member. The female member is configured to receive the male member of a vertically adjacent panel therein and has a locking slot. The structural panel also includes a locking member operatively engageable to the male member and configurable between an unlocked configuration where it does not substantially project outside of lateral wall surfaces of the male member and a locked configuration where it projects outside of at least one of the lateral wall surfaces of the male member and is engaged in the locking slot of the vertically adjacent panel. A panel assembly, a method for building a building wall using multiple structural panels, a corner securement assembly for at least two horizontally adjacent structural panels and a method for securing two horizontally adjacent panels in a corner configuration are also provided.