Water-impervious Wall Panel with Interlocking Tongue-and-Groove Joint

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Solution Overview

Problem

Current wall panels for bathrooms require extrusions and silicone seals to prevent water ingress, which detract from aesthetics and maintenance, and the silicone seals degrade over time, compromising the integrity of the installation.

Innovation Solution

A water-impervious wall panel system featuring a wood plastic composite or stone plastic composite core with a decorative laminate and tongue-and-groove interlocking edges, eliminating the need for extrusions and enhancing installation simplicity and aesthetic appeal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional wood-based substrates with unfinished edges are used, then the panel can be manufactured with simple structure, but extrusions and silicone seals are required to prevent water ingress, which detract from aesthetics and require maintenance

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidrequirement for extrusions and silicone seals

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent uses composite materials (wood plastic composite or stone plastic composite core combined with decorative laminate) to create a panel that is both aesthetically pleasing and water-impervious, eliminating the need for separate protective components like extrusions and silicone seals

Inventive Principle:

Principle #40Composite materials

2Reliability

If silicone seals are used to prevent water ingress, then water protection is achieved, but the silicone seal breaks down over time and needs replacing

Engineering Contradiction:

Improvewater protectionVSAvoidservice life of silicone seal

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent extracts and eliminates the silicone seal component entirely by incorporating water protection directly into the panel structure through water-impervious materials and tongue-and-groove interlocking edges, removing the source of future maintenance needs

Inventive Principle:

Principle #2Taking out (Extraction)

3Shape

If tongue-and-groove interlocking system with contact area across less than width is used, then tight joint without visible gaps is achieved, but manufacturing precision requirements increase

Engineering Contradiction:

Improvetight joint without visible gapsVSAvoidedge precision requirement

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The patent applies local quality by concentrating the interlocking contact area at the front face of the panel rather than across the entire width, creating a tight visible joint where needed while reducing precision requirements in other areas

Inventive Principle:

Principle #3Local quality

4Reliability

If laminate is attached to both major surfaces of the core, then water-impervious properties are improved, but manufacturing complexity increases

Engineering Contradiction:

Improvewater-impervious propertiesVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies universality by using the same laminate attachment process on both major surfaces of the core, allowing a single manufacturing procedure to achieve water protection on multiple surfaces simultaneously

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

The system provides a durable, aesthetically pleasing, and maintenance-friendly solution by ensuring a tight joint without visible gaps, reducing the need for frequent replacements and enhancing insulating properties to prevent condensation.

Implementation Method 1

A laminate is adhesively attached to the core

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

One of the tongue-and-groove edges of the intermediate first wall panel and the tongue-and-groove edge of the end second wall panel form an interlocking system

Methodology Applied

Scientific EffectMechanical interlocking: Mechanical Fastener

Implementation Method 3

enhancing insulating properties to prevent condensation

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS11746535B2Impervious wall panel

Publication Date: 2023.09.05 BUSHBOARD

AI summary

A water impervious wall panel system includes an intermediate first wall panel composed of a waterproof core and a decorative surfacing attached to the core, wherein the intermediate first wall panel is provided with tongue-and-groove edges. The water impervious wall panel system also includes an end second wall panel composed of a waterproof core and a decorative surfacing attached to the core, wherein the end second wall panel is provided with a tongue-and-groove edge and a rolled edge. One of the tongue-and-groove edges of the intermediate first wall panel and the tongue-and-groove edge of the end second wall panel form an interlocking system having a contact area adjacent to a front face of the intermediate first wall panel and the end second wall panel and a gap adjacent a rear face of the intermediate first wall panel and the end second wall panel, the contact area surface extending across less than the thickness of the intermediate first wall panel and the end second wall panel so as to provide a tight joint at the front face and eliminate visible gaps.