Modular Connector Kit for Prefabricated Panels
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Solution Overview
Problem
Existing methods for connecting prefabricated construction panels, such as precast ferroconcrete elements, often require on-site wet works, welding, or screw connections, which are time-consuming and can lead to thermal bridges and increased construction costs.
Innovation Solution
A three-piece connector kit consisting of two plug sockets and one flat plug connector, where the plug sockets have a sinusoidally bent plane profile and a semicircular cavity for reinforcing bars, allowing for quick and durable connections without the need for liquid mortar or screw connections, and can be used for both in-line and corner connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connection methods (wet works, welding, screw connections) are used to connect prefabricated panels, then the connection strength and reliability are improved, but the construction time increases and thermal bridges are created
Solution Approach 1:
The connection system is divided into separate modular components: a connection element with a receiving cavity and a connecting element with a protrusion. These segmented parts are pre-assembled in the factory and connected on-site through simple insertion, eliminating the need for time-consuming wet works or welding while maintaining connection reliability through precise geometric matching and mechanical interlocking.
Solution Approach 2:
The connection elements are pre-assembled in the factory before the panels are shipped to the construction site. This preliminary action includes positioning the connection elements, ensuring proper alignment, and preparing the interfaces. On-site, the connection is achieved through simple insertion without requiring additional assembly steps, significantly reducing construction time while ensuring reliable connections.
2Reliability
If traditional connection methods are used, then the connection durability is improved, but the construction costs increase due to additional materials and labor
Solution Approach 1:
The connection system extracts and eliminates the need for additional connection materials such as mortar, welds, or screws. The connection is achieved through direct mechanical interlocking of the pre-assembled elements, removing the need for separate connection materials and the labor associated with applying them, thereby reducing construction costs while maintaining durability through the robust geometric connection.
Solution Approach 2:
The connection elements are designed to be self-aligning and self-securing through their geometric shapes. The protrusion on one element automatically fits into the receiving cavity of the mating element, creating a stable connection without requiring additional fasteners, adhesives, or complex assembly procedures. This self-service mechanism reduces both material costs and labor costs while ensuring durable connections.
3Reliability
If profiled recesses or protrusions are used for panel connection, then the structural tightness is improved, but the manufacturing complexity increases
Solution Approach 1:
The connection elements are designed as universal components that can be applied to various panel types and connection locations. The standardized geometric shapes of the receiving cavities and protrusions allow the same connection system to be used across different panel configurations, simplifying manufacturing by using repeated, standardized forms rather than custom-profiled recesses for each connection point.
Solution Approach 2:
The complex geometric profiling is performed during factory pre-assembly of the connection elements, not during on-site panel manufacturing. This preliminary action allows the use of precise, complex geometric shapes for structural tightness while keeping the actual panel manufacturing simple, as the profiling is done in the controlled factory environment using specialized equipment, and the panels themselves require only standard production processes.
Data Source
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AI summary
Connection kit for fastening precast elements, of a connector whose one part is placed in the structure of one precast element, and another piece is placed in the structure of an adjacent precast element, fitted with a plug socket and a shape-matched plug connector which unites the two precast elements by fitting into the socket. The kit consists of two plug sockets (A, B), positioned in two precast elements to be connected (Pa, Pb) and one flat plug connector (S), the shape of which resembles a very low, wide and thick letter U with the profile of a sinusoidally bent plane; the cross-section of the connector has the shape of a wedge tapering towards the end that is hammered into plug sockets (A, B), while each of the plug sockets (A, B) is fitted with a rectangular flat element (1a, 1b) situated in the part of the housing that is located in the external plane of the precast panel element to be connected (Pa, Pb) and has an internal gap (2a, 2b) whose shape matches a half of the plug connector (S), whereas the part of the plug socket (A, B) located inside the element to be connected has a semicircular cavity (3a, 3b) to accommodate a reinforcing bar (13a, 13b). A method of connecting precast panels using such connecting kit consists in that: already in the prefabrication plant, at least one plug socket (optionally socket (A) or socket (B) or socket (B 2)) is inserted inside the structure of each precast element depending on its intended use and function (parallel element or corner element), such socket being inserted so that the line that goes along the contact edge of the connected elements is their axis of symmetry. Subsequently, on the construction site, immediately prior to connecting two adjacent precast elements, those elements are placed in relation to each other so that their plug sockets - socket (A) or socket (B) or socket (B2 ) are positioned on the opposite sides of their symmetry plane and are positioned in the contact plane of the elements to be connected; in order to connect the elements.