Lightweight Panel Anchoring Using Vibration-Flow Thermoplastic Connectors
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Solution Overview
Problem
Lightweight building elements with thin layers and non-penetrable interlinings pose challenges for secure anchoring of connectors, leading to reliance on adhesive bonds that lack reliability and increase manufacturing costs.
Innovation Solution
A method involving mechanical vibration to liquefy thermoplastic material within the building element, allowing the connector to be anchored without disrupting the outer surface, and optionally marking the anchoring location for future attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive bonds are used to attach objects to lightweight building elements, then the anchoring reliability can be improved, but the manufacturing cost and time increase due to slow hardening processes and material costs
Solution Approach 1:
The patent replaces the chemical bonding mechanism (adhesive hardening) with a mechanical anchoring mechanism. A connector with anchoring structures is inserted into the lightweight building element, where the anchoring structures mechanically interlock with the material matrix, providing immediate mechanical strength without requiring chemical curing time.
Solution Approach 2:
The patent utilizes the porous or fibrous structure of the lightweight building element's interlining material to enable mechanical anchoring. The connector's anchoring structures (such as hooks, bars, or interlocking features) engage with the voids and fibers within the porous material, creating a mechanical interlock that provides reliable attachment while maintaining the lightweight structure's integrity.
2Reliability
If adhesive bonds are used to attach objects to lightweight building elements, then the anchoring reliability can be improved, but the manufacturing cost increases due to material cost and slow hardening processes
Solution Approach 1:
The patent replaces the chemical bonding mechanism (adhesive hardening) with a mechanical anchoring mechanism. A connector with anchoring structures is inserted into the lightweight building element, where the anchoring structures mechanically interlock with the material matrix, providing immediate mechanical strength without requiring chemical curing time.
Solution Approach 2:
The patent employs connectors made from cost-effective materials that provide reliable mechanical anchoring without the need for expensive adhesive materials. The connectors are designed as simple mechanical components that can be mass-produced at low cost, eliminating the need for costly adhesive materials and associated application equipment.
3Reliability
If the connector is anchored in the lightweight building element, then the attachment reliability is improved, but the outer surface integrity may be compromised
Solution Approach 1:
The patent extracts the anchoring function from the outer surface by inserting connectors through pre-defined access points or openings in the building layers. The anchoring structures engage with the interlining material from the interior side, allowing mechanical attachment without compromising the aesthetic or structural integrity of the outer surfaces.
Solution Approach 2:
The patent designs connectors with nested or telescopic structures that can be inserted through openings and then expanded or locked into position within the building element. The anchoring structures are contained within the building element's thickness, preventing protrusion or damage to the outer surfaces while maintaining secure attachment capability.
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
Provides a reliable and cost-effective anchoring method that maintains the integrity of the building element's surface while ensuring secure attachment of additional objects, reducing manufacturing delays and costs.
Implementation Method 1
causing mechanical vibrations to act on the first object from a proximal end face thereof while the first object and the connector are pressed against each other, until material at the proximal end of the connector is at least partially flowable
Implementation Method 2
causing mechanical vibration energy to impinge on the first object from a proximal end face thereof
Implementation Method 3
causing the flowable material to flow into structures of the connector
Implementation Method 4
while the first object and the connector are pressed against each other
Data Source
Figure 1a~2
Figure 3~4
Figure 5~6
AI summary
According to an aspect of the present invention, a method of anchoring a connector (3) in a first object is provided, the connector comprising a thermoplastic material in a solid state, the method comprising - providing the first object and the connector (3); - bringing the connector into contact with the first object from a distal side thereof, - causing mechanical vibration energy to impinge on the first object from a proximal end face thereof, the proximal end face being opposite the distal side, while the object and the connector are pressed against each other, until of the first object is compressed yielding compressed material (14) and a proximally facing end of connector is at least partially flowable forming a flow portion of the thermoplastic material, and causing the flow portion to flow into structures of the compressed material (14) of the first object and/or a vicinity thereof, and - letting the flow portion re-solidify to cause a positive-fit connection between the first object and the connector (3).