Toolless Ceiling Panel Locking Element with Resilient Rod
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Solution Overview
Problem
Existing ceiling panel systems face difficulties in tool-free assembly and disassembly, especially under high loads, due to the need for horizontal movement and the risk of injury from protruding hooks, and they often result in an unsightly appearance and high production costs.
Innovation Solution
A locking element comprising a resilient bearing rod clamped in a locking plate, where the free end forms a load-bearing connection with a locking hook, allowing tool-free operation by using the locking hook itself to actuate the connection, enabling easy assembly and disassembly without horizontal movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If spring-loaded latches are actuated using a cable pull with a hand-operated hook, then tool-free installation is achieved, but it poses a risk of injury and creates an unsightly appearance with protruding hooks
Solution Approach 1:
The harmful protruding hook is extracted and replaced by a recessed control opening in the locking plate. The actuating mechanism is moved from an external cable pull with protruding hook to an internal control opening that receives a flat-bladed tool, eliminating the safety hazard and aesthetic defect while preserving tool-free operation capability
Solution Approach 2:
A flat-bladed control tool is introduced as an intermediary between the operator and the locking mechanism. This tool can be inserted through the control opening to actuate the spring-loaded latch without requiring protruding elements, thereby mediating between the need for tool-free operation and the elimination of harmful protrusions
2Reliability
If ceiling panels require both vertical lifting and horizontal travel path for removal, then locking mechanism provides secure attachment, but it makes installation difficult and prevents minimizing slot width
Solution Approach 1:
The traditional locking mechanism requiring horizontal travel for engagement is inverted. The spring-loaded latch automatically engages vertically during insertion, and release is achieved by vertical pressing action through the control opening rather than horizontal manipulation. This inverts the operation direction and eliminates the need for horizontal travel path
Solution Approach 2:
The locking mechanism is designed to self-engage during vertical insertion without requiring horizontal alignment or travel. The spring-loaded latch automatically snaps into the locked position when the ceiling panel is inserted vertically, providing secure attachment through self-service action and eliminating installation complexity
3Device complexity
If curved spring hook is used for load-bearing connection, then simple design is achieved, but high load-bearing capacities cannot be applied as the spring hook would bend
Solution Approach 1:
The spring element parameters are changed from a curved spring hook with limited load capacity to a resilient support rod with optimized dimensions and material properties. The support rod is designed with sufficient stiffness and strength to withstand high loads while maintaining the spring-loaded actuation mechanism, thereby increasing load-bearing capacity without significantly increasing device complexity
Solution Approach 2:
The locking element is designed as a composite structure combining a resilient support rod (providing both structural strength and spring functionality) with a locking plate and latch mechanism. This composite design integrates load-bearing and locking functions in a unified structure that achieves both high strength and simple design
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
This solution allows for tool-free assembly and disassembly of ceiling panels under high loads, reducing assembly costs and maintaining a visually appealing, seamless ceiling appearance by eliminating the need for horizontal movement and minimizing butt joints.
Implementation Method 1
a resilient support rod (11) clamped on one side in the locking plate (10), the free spring-loaded end (22) of which forms a load-bearing connection with the locking hook (3, 4)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A suspended ceiling consisting of individual, rectangular or square ceiling panels (1, 2) laid in a grid pattern, which can be attached to a structural ceiling or other supporting structure (13) without tools and which have locking hooks (3, 4, 23) on one side of the fastening plane, which can be locked to locking plates (10) arranged on the opposite fastening plane, wherein a resilient support rod (11) is fixed in the locking plate (10), the free resilient end (22) of which engages a locking slot (9) on the side of the panel, through which a hook head (8) of the locking hook (3, 4, 23) can be inserted and locked to the free resilient end (22) of the support rod (11).