Dovetail Panel Coupling for Precise Prefabricated Alignment
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Solution Overview
Problem
Existing coupling systems for prefabricated building panels often result in misalignment due to imperfect fastening of metal foil keys with plastic locking elements, leading to increased production costs and reduced lifespan, and are not suitable for panels with dovetail-shaped grooves.
Innovation Solution
A coupling system using metal tapered elements with symmetrical wings and a foil key that rotates to secure the panels in dovetail grooves, ensuring optimal grip and alignment without the need for additional protruding profiles or rivets, allowing for easy and cost-effective assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a metal foil key is mechanically fastened to a plastic locking element, then the connection process is simplified, but the foil key cannot be perfectly orthogonal and panel alignment is compromised
Solution Approach 1:
A positioning element is introduced as an intermediary component between the foil key and the locking element. This positioning element ensures perfect orthogonality during fastening, allowing the foil key to be mechanically attached while maintaining precise panel alignment through the mediating positioning structure.
Solution Approach 2:
The positioning element is pre-configured with orthogonal geometry before the fastening process. By preparing the positioning structure in advance with the correct angular relationship, the system ensures that when the foil key is fastened to the locking element, the panels automatically achieve perfect alignment without requiring post-adjustment.
2Ease of manufacture
If material is removed from the locking element to fasten the foil key, then the foil key can be attached, but coplanarity of panel surfaces is compromised
Solution Approach 1:
The positioning element serves as a mediator that bridges the foil key and locking element without requiring material removal from the locking element. This intermediary structure provides the necessary attachment points for the foil key while preserving the intact geometry of the locking element, thereby maintaining surface coplanarity.
3Ease of manufacture
If the locking element is made of plastic, then the system is cost-effective and easy to manufacture, but the lifespan is reduced
Solution Approach 1:
The system employs a composite material strategy where the locking element is made of plastic for cost-effectiveness and ease of manufacture, while the positioning element and foil key are made of metal for enhanced durability and lifespan. This composite approach allows each component to be made from the most suitable material for its specific functional requirements.
4Duration of action of stationary object
If the locking element is made of metal, then the lifespan is improved, but the dimensional tolerance field is significantly narrowed
Solution Approach 1:
The positioning element acts as a mediator that absorbs dimensional variations and tolerance deviations. By introducing this intermediary component with appropriate tolerance design, the system can use metal locking elements for durability while the positioning element compensates for manufacturing variations, preventing the narrow tolerance field from becoming a critical constraint.
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 ensures parallel alignment of prefabricated panels with dovetail grooves, providing a sturdy and cost-effective solution with improved manufacturing simplicity and reliability, while maintaining a quick and simple connection process.
Implementation Method 1
a foil key (110) being fast connected to said coupling element (120), said foil key (110) being configured to rotate said coupling element (120) from a first position, in which each of said coupling elements (120) is free to slide, to a second position, in which said coupling elements (120) are constrained to each other and to said first and second prefabricated panels (200) in a fixed position
Implementation Method 2
said coupling elements (120) being inserted into said grooves (250) so that said coupling elements (120) grip said grooves (250) with said second length substantially oriented along said grooves (250)
Data Source
AI summary
Provided is a system of prefabricated panels couplable by a coupling device engaged in grooves with dovetail-shaped cross sections, each groove having two mutually facing steps. The coupling device has a metallic coupling element having a first and a second tapered elements with height along a vertical axis and symmetrical with respect to a first plane perpendicular to the vertical axis. A foil key rotates the coupling element from a rest position, in which each tapered element is inserted into a respective groove and free to move along the respective groove, to a locked position, in which each tapered element is inserted into the respective groove and constrained to the respective groove along the first reference plane, and vice versa. Each tapered element has a first and a second wings symmetrical with respect to a second reference plane and extending along the vertical axis with ends for engaging the steps.