Double-Skin Panel Push-Fit Assembly With Concealed Sheet Edges
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Solution Overview
Problem
Existing double skin panels for HVAC systems are labor-intensive to assemble due to the need for welding or riveting, and exposed cut edges pose an injury hazard to installation engineers.
Innovation Solution
A double skin panel constructed from two folded flat metal sheets with integral connection members, featuring a push-fit arrangement using catch members and recesses, eliminating the need for welding or riveting and concealing sharp edges within the folded structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding or riveting is used to join panel skins, then connection strength is improved, but assembly time and labor intensity increase
Solution Approach 1:
The connection system is divided into separate components: a connection element with engagement features and a corresponding recess in the panel skin. This segmentation allows for pre-fabricated modules that can be quickly assembled without time-consuming welding or riveting processes, while maintaining connection strength through the interlocking geometry of the segmented parts.
Solution Approach 2:
The patent replaces traditional mechanical joining methods (welding, riveting) with a snap-fit or press-fit mechanical engagement system. The connection element features geometric engagement surfaces that interlock with recesses in the panel skin, providing sufficient connection strength through friction and geometric interlocking rather than permanent mechanical fastening, thereby dramatically reducing assembly time.
2Strength
If welding or riveting is used to join panel skins, then connection strength is improved, but device complexity increases
Solution Approach 1:
The connection element is designed to integrate multiple functions into a single component: it provides structural support, creates the mechanical connection through engagement features, and may incorporate sealing surfaces. This merging eliminates the need for separate fasteners, gaskets, and alignment fixtures required by welding or riveting systems, reducing overall device complexity while maintaining connection strength.
Solution Approach 2:
The connection element is designed as a universal component that can be used across different panel configurations and locations. The standardized engagement features and recesses allow the same connection element design to be applied throughout the HVAC system, eliminating the need for custom-designed fasteners for each joint and simplifying the overall connection system.
3Ease of manufacture
If folded metal sheets with exposed edges are used, then manufacturing simplicity is improved, but safety hazards increase
Solution Approach 1:
The connection element is nested within a recess formed in the panel skin, with the engagement features positioned inside the panel thickness. This nesting arrangement conceals the sharp edges of the folded metal sheets within the panel structure, exposing only smooth, rounded surfaces to external contact, thereby eliminating injury hazards while maintaining the manufacturing simplicity of folded sheet construction.
Solution Approach 2:
The potentially harmful sharp edges created by folding metal sheets are converted into beneficial engagement surfaces. The fold lines that create sharp edges are strategically positioned to form the connection element's engagement features, which interlock with recesses in the panel skin. Thus, the folding process that creates hazards also creates the mechanical connection mechanism, turning the harmful sharp edges into functional, concealed connection surfaces.
Data Source
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AI summary
A panel (10) comprising a first wall section (2) and a second wall section (4) configured to be at least partially received within the first wall section (2). The first wall section (2) comprises a first connection member (34) and the second wall section comprises a second connection member (30). The first and second connection members (34)(30) are arranged such that they engage when the second wall section (4) is inserted into the first wall section (2) to hold the first and second wall sections (2)(4) together.