Flush-Coupled Worktop Assembly for Steel and Composite Slabs
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Solution Overview
Problem
The existing methods for coupling large steel slabs with slabs of different materials, such as wood or plastic, in worktops like kitchens face challenges due to material torsion and structural differences, leading to difficult, costly, and imprecise assembly, with increased risk of breakage during transportation and installation.
Innovation Solution
A method involving a depression zone in the second slab to accommodate the steel slab, with a supporting perimeter of lower height, using a packing or dry packing and optional glue, and an external channel to ensure flush coupling, allowing for easy assembly and reduced risk of breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional coupling systems (adhesives, screws, hooks) are used to join steel slabs with other materials, then the slabs can be joined together, but the different structural capacity and torsion of materials make flush coupling impossible or require difficult, costly, and imprecise assembly systems
Solution Approach 1:
The patent introduces an intermediary element (depression zone with supporting perimeter) between the steel slab and the other slab to mediate the coupling. This intermediary structure accommodates the dimensional differences and torsional stresses between dissimilar materials, enabling precise flush coupling without complex assembly systems.
Solution Approach 2:
The patent changes the geometric parameters of the coupling interface by creating a depression zone with specific depth and a supporting perimeter with controlled height. This parameter modification allows the steel slab to be properly positioned and flush-coupled with the other slab despite material differences.
2Strength
If conventional coupling systems are used to join slabs of different materials, then the slabs can be joined, but the structure loses the solidity it needs for use
Solution Approach 1:
The depression zone acts as an intermediary that distributes loads and stresses evenly between the steel slab and the other slab, maintaining structural solidity. The supporting perimeter within the depression zone provides additional mechanical support without requiring complex external coupling systems.
Solution Approach 2:
The patent moves the coupling mechanism from a surface-level interface to a three-dimensional depression zone with vertical depth. This dimensional change allows for better stress distribution and stronger structural connection between the dissimilar materials.
3Reliability
If slabs are coupled flush before installation and must be subsequently packed and dispatched, then the assembly is complete, but there is a greater risk of breakage because the play between materials with different resistances is not absorbed
Solution Approach 1:
The depression zone serves as a pre-built cushioning structure that absorbs dimensional play and stress between materials with different resistances. This beforehand cushioning prevents breakage during transportation and installation while maintaining the simplicity of the assembly process.
Solution Approach 2:
The patent modifies the geometric parameters of the coupling interface by creating a depression zone with specific depth and a supporting perimeter, which provides stress absorption capacity. This parameter change enables the structure to withstand transportation stresses without increasing assembly complexity.
4Strength
If very resistant glues, cross-pieces, moldable rubber, or tension brackets are used to overcome material differences, then the slabs can be joined, but they are not satisfactory because they are not suitable for the stresses typical of cooking tops or work tops and cannot keep the slabs coupled flush due to the large hole
Solution Approach 1:
The depression zone with supporting perimeter serves as a structural intermediary that provides mechanical support and maintains flush coupling precision. This intermediary structure is specifically designed to handle the stresses typical of cooking tops and work tops, overcoming the limitations of conventional coupling methods.
Solution Approach 2:
The patent transitions from two-dimensional surface coupling to three-dimensional depression zone coupling. This dimensional change provides the necessary structural support to maintain flush coupling precision while withstanding heavy loads and stresses.
Data Source
Figure 1~5
AI summary
Top (10), even large size, made by coupling at least two slabs, one slab (11) made of steel with an irregular shape and one slab (12) made of another known material. The coupling is flush and occurs through depression with the at least partial overlapping of the slab (11) in correspondence with the supporting perimeter (14) of the slab (12).