Wall Panel Edge Coupling for Thermal Expansion Movement
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Solution Overview
Problem
Existing wall or ceiling panels face issues with thermal expansion and shrinkage, leading to gaps, doming, loosening, or breakage due to fixed installation methods, and require costly connection members with specific profiles for free movement.
Innovation Solution
Wall or ceiling panels with mechanical coupling parts on opposite edges and a backing layer covering the surface, extending beyond the edges, allowing for flexible installation and compensation for expansion/shrinkage, and connection members that engage with these edges to provide support and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If panels are fixed to wall or ceiling using gluing, nailing or screwing, then installation is simple and panels are securely attached, but panels cannot accommodate thermal expansion and shrinkage leading to gaps, doming, loosening or breakage
Solution Approach 1:
The patent applies the dynamics principle by transitioning from a fixed attachment system to a dynamic one where the panel can move relative to the connection member. The connection member allows the panel to slide freely in the direction of thermal expansion and shrinkage while maintaining secure attachment perpendicular to the wall or ceiling surface. This dynamic capability enables the panel to accommodate dimensional changes without compromising attachment security.
2Adaptability or versatility
If connection members are designed to allow free panel movement, then thermal expansion and shrinkage are accommodated, but connection members require special profiles and high strength leading to increased cost
Solution Approach 1:
The patent applies segmentation by dividing the connection function into two independent components: the connection member that attaches to the wall or ceiling, and the panel that carries the mechanical coupling parts. This segmentation allows each component to be optimized independently - the connection member can be simple and cost-effective while the panel incorporates the specialized profiled edges for movement accommodation.
Solution Approach 2:
The patent inverts the traditional approach by placing the specialized profiled edges (mechanical coupling parts) on the panel rather than on the connection member. This inversion simplifies the connection member design, making it a simpler element that can be easily attached to the wall or ceiling, while the panel bears the complexity of the profiled edges needed for thermal movement accommodation.
3Reliability
If connection members are made with high strength requirements, then panel support and movement freedom are achieved, but manufacturing cost increases
Solution Approach 1:
The patent applies segmentation by dividing the structural requirements between the panel and the connection member. The panel, being a larger and more substantial element, carries the mechanical coupling parts and provides the primary structural support. The connection member can be simpler and less expensive, serving mainly to attach the panel to the wall or ceiling and allow thermal movement, rather than bearing heavy loads.
Data Source
AI summary
A wall or ceiling panel includes a substrate layer and a top layer. The substrate layer, on at least one pair of opposite edges, is provided with mechanical coupling parts, and a backing layer is provided onto the surface of the substrate layer opposing the top layer, which backing layer at least partly covers the substrate layer. The backing layer at least partly extends beyond one of the edges. An assembly of a wall or ceiling panel, and a A connection member for an assembly of a wall or ceiling panel is configured to connect to the mechanical coupling parts on at least one of the edges of the substrate layer, and to at least partly extend beyond one of the edges of the substrate layer.