Composite Panel Facade Mounting With Keyhole Rivet Locking
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Solution Overview
Problem
Existing fastening methods for composite panels in building envelopes, such as screw connections, are prone to misalignment, require complex adjustments, and may loosen due to temperature fluctuations and wind forces, lacking a reliable and secure attachment solution.
Innovation Solution
A method using a pull-through rivet with a mushroom-shaped head and a continuous axial through-hole, combined with a setting tool, creates a positive connection by reshaping the rivet shank to form a bead, ensuring a secure and backlash-free attachment of the panel holder to the composite panel through keyhole-shaped grooves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If screw connections are used to fasten panel holder to composite panel, then the fastening method is simple to implement, but the connection may loosen due to temperature fluctuations and wind forces
Solution Approach 1:
The fastening system is segmented into distinct functional components: the panel holder with integrated fastening elements, the composite panel with pre-formed keyhole grooves, and the substructure. This segmentation allows each component to be optimized independently - the panel holder provides simple installation while the rivet-to-keyhole mechanism provides reliable, weather-resistant connection that prevents loosening.
Solution Approach 2:
The keyhole-shaped grooves are pre-formed in the composite panel during manufacturing, and the panel holder is pre-configured with fastening elements. This preliminary preparation eliminates the need for complex on-site adjustments and ensures proper alignment, allowing simple implementation while maintaining high reliability through the pre-engineered connection geometry that resists temperature and wind-induced loosening.
2Ease of operation
If traditional fastening methods are used, then installation is straightforward, but misalignment and complex adjustments are required
Solution Approach 1:
The keyhole-shaped groove features an asymmetric geometry with a narrow slot portion and a widened insertion opening. This asymmetric design guides the fastening element through the insertion opening into the slot portion, automatically self-aligning the panel holder with the composite panel during installation. The asymmetry eliminates the need for complex adjustments while ensuring precise alignment, combining installation simplicity with manufacturing precision.
3Reliability
If secure attachment is achieved through complex fastening mechanisms, then reliability improves, but device complexity increases
Solution Approach 1:
The panel holder integrates multiple functions into a single component: it provides structural support for the composite panel, incorporates the fastening elements directly into its structure, and includes alignment features. This merging eliminates the need for separate fasteners, alignment tools, and locking mechanisms, achieving high attachment security through a simple, unified design that reduces overall system complexity.
Solution Approach 2:
The fastening system is designed to be self-aligning and self-securing. The keyhole-shaped groove automatically guides the fastening element into the correct position, and the rivet-to-keyhole connection self-locks to prevent loosening. This self-service capability eliminates the need for complex adjustment mechanisms, locking devices, or specialized installation tools, maintaining reliability while minimizing device complexity.
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 method provides a reliable, secure, and adjustable fastening solution that withstands environmental forces, allows for easy reusability, and maintains precise alignment without the need for additional locking mechanisms.
Implementation Method 1
the free end of the shank is reshaped by a rivet setting tool so that the rivet creates a positive connection between the composite panel and the panel holder
Data Source
Figure 1~2
Figure 3~4
Figure 5A~5C
AI summary
A method for producing a fastening arrangement from a composite panel 100 and a panel holder 200 is described. The composite panel 100 is designed as a sandwich panel with a rear cover sheet 130, a front visible sheet 110 and an intermediate core layer 120. At least one keyhole-shaped groove 150 is provided on the rear side 140 of the composite panel 100. This has a widened insertion opening 152 at its first longitudinal end and a slot-shaped holding area 154 with an undercut 156 in the core layer 120 at the other longitudinal end. The mechanical connection between the composite panel 100 and the panel holder 200 is achieved by a setting process and a resulting rivet connection in that a rivet 390 with a mushroom-shaped head 320 and a shaft 310 is threaded with its head 320 through the insertion opening 152 and then placed in the undercut of the holding area of the groove in the composite panel.The free end of the rivet shank thus protrudes from the rear cover plate. The plate holder 100 is placed onto the free end of the rivet shank via a through-hole, so that the plate holder 200 rests on the cover plate 130. The free end of the shank 310 is then reshaped by a rivet setting tool so that the rivet 390 creates a positive connection between the composite plate 100 and the plate holder 200. The rivet 390 is preferably designed as a pull-through rivet, the shank 310 and head 320 of which have a continuous axial through-hole 315 with a diameter DI, into which a mandrel can be inserted. The fastening arrangement refers to the connection of a composite plate and a plate holder, which is realized by the method described above.A facade arrangement of composite panel facade elements on a building structure comprises a substructure attached to a building structure with at least one profile support and a plurality of composite panels 100 and panel holders, manufactured using fastening arrangements which in turn are realized by the method described above.