Wall Panel Profiled Edge Interlock Design
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Solution Overview
Problem
Existing wall panels for building façades have limitations such as restricted mounting direction, complex installation, increased friction, and potential ice formation due to design, which hinder accurate and fast mounting and may lead to additional forces on the sub-structure.
Innovation Solution
The wall panel design features profiled edges with a male and female portion, including protruding parts and flanged edge portions, allowing for secure interlocking, reduced contact area, and drainage to prevent water ingress, along with spring clips for safety locking and adjustable mounting brackets for versatile installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wall panels are mounted directly to sub-construction using screws or modular rails, then the panels can be fixed securely, but the mounting process becomes complicated and time-consuming
Solution Approach 1:
The patent introduces an intermediary connection system where the male and female profiled edges act as mediators between wall panels. These profiled edges provide both mechanical interlocking for secure fixing and guide features for rapid alignment, eliminating the need for complex mounting procedures while maintaining reliable connection.
2Ease of operation
If wall panels are mounted in a single direction, then the installation process is simplified, but the design lacks versatility for different building configurations
Solution Approach 1:
The patent employs asymmetric design in the male and female profiled edges, where the geometric features are designed to accommodate insertion from multiple directions. The asymmetric geometry includes chamfered surfaces and tapered portions that guide panel alignment regardless of approach direction, enabling versatile installation while maintaining operational simplicity.
3Strength
If the contact area between successive wall panels is increased, then the structural connection is strengthened, but friction increases making positioning difficult
Solution Approach 1:
The patent applies local quality by concentrating the contact area between successive wall panels at specific strategic locations within the profiled edges. Rather than increasing overall contact area, the design features localized contact zones at the interface of male and female portions that provide sufficient connection strength while maintaining low friction for easy positioning.
4Strength
If the profiled edges are designed with extensive contact surfaces, then the interlocking is stronger, but ice formation between panels is promoted
Solution Approach 1:
The patent extracts or removes potential water accumulation zones from the profiled edge design. The geometry is configured to prevent water pooling between male and female portions, eliminating the condition necessary for ice formation. This is achieved through tapered interfaces and drainage-oriented features that maintain strong interlocking while preventing harmful ice accumulation.
Data Source
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Figure 5~6
AI summary
Wall panel (1) for a facade element of a building comprising a plurality of successive wall panels wherein the wall panel is provided with a first (2) and a second (3) profiled edge at opposite sides of an intermediate part (10) of the wall panel wherein the first profiled edge is shaped into a male portion and the second profiled edges into a mating female portion, wherein the profiled edges are shaped to provide a good interlock between the profiled edges.