Modular Panel Connector Assembly for High Wind Load Resistance
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Solution Overview
Problem
Modular polymeric panels face limitations in size versatility, high wind load resistance, and compatibility with various panel types, leading to increased costs and maintenance needs in applications like greenhouses and solar roof collectors.
Innovation Solution
A connector assembly comprising side collectors and clips with energy directors, designed to securely attach panels of varying sizes and thicknesses, providing structural integrity and preventing separation under high wind loads through snap-fit or sliding mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If modular polymeric panels are used to reduce weight and improve insulation, then operational and maintenance expenses are reduced, but the panels are limited in size versatility and require expensive retooling for non-standard widths
Solution Approach 1:
The panel system is divided into modular units with standardized connection edges. The connector assembly separates the panel body from the connection mechanism, allowing panels to be segmented into standard sizes while maintaining versatility through modular connectors that can accommodate different panel configurations without requiring retooling of the panels themselves.
Solution Approach 2:
The connector assembly is designed with universal functionality to work with panels of varying sizes and types. The side collectors and clips provide a standardized interface that can connect different panel widths and thicknesses, eliminating the need for custom connection solutions for each panel size and reducing the requirement for expensive retooling.
2Illumination intensity
If glass panels are used to provide good light transmission, then natural light can shine into structures, but the high weight requires structural reinforcements increasing initial costs
Solution Approach 1:
The patent replaces heavy glass panels with lighter polymeric panels that maintain adequate light transmission properties. The connector assembly provides a mechanical system specifically designed for polymeric materials, using features like energy directors for ultrasonic welding and snap-fit mechanisms that are optimized for plastic materials rather than glass, thereby reducing weight while maintaining structural integrity and light transmission.
3Illumination intensity
If glass panels are used for roofing structures, then light transmission is achieved, but poor insulating ability results in higher heating expenses
Solution Approach 1:
The patent employs multiwall polymeric panels with internal air chambers or vacuum insulation layers that provide superior thermal insulation compared to solid glass panels. The connector assembly is designed to maintain the integrity of these insulating structures at the panel joints, preserving the thermal performance while allowing for modular assembly. The polymeric materials themselves have better insulating properties than glass, reducing heat loss and heating expenses.
4Ease of operation
If modular panels are used for ease of installation, then assembly is simplified, but the panels cannot be cut to desired sizes without loss of connecting edges
Solution Approach 1:
The connector assembly is segmented into separate components (side collectors, clips, connectors) that can be independently attached to panels. This allows panels to be cut to custom sizes after manufacture, and the connector components can be repositioned or reattached to maintain the modular connection system. The separation of connection elements from the panel body enables flexibility in panel sizing while preserving ease of installation.
Solution Approach 2:
The connector assembly incorporates dynamic or adjustable features that allow adaptation to different panel configurations. The clips and connectors can be positioned at various locations along the panel edges, and the side collectors can accommodate different panel widths, enabling custom size configurations while maintaining the simplified modular installation process.
5Ease of manufacture
If modular panels are used to reduce initial costs, then installation expenses are lowered, but wind loads can pull panels off supports leading to premature failure
Solution Approach 1:
The connector assembly incorporates curved or angled features in the side collectors and clips that distribute wind load forces more effectively. The geometry of the connectors is designed to resist uplift forces from high wind loads, with curved surfaces that redirect forces along the panel support structure rather than concentrating stress at single attachment points, thereby preventing panel detachment while maintaining cost-effective modular installation.
Solution Approach 2:
The connector assembly is pre-engineered with features that anticipate and prepare for wind load conditions. The side collectors and clips are designed with sufficient strength and attachment surface area to withstand high wind pressures from the outset. Energy directors and welding features are pre-configured to create strong bonds before wind loads are applied, ensuring reliability is built into the installation rather than added as a corrective measure.
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
Enhances the ability of panels to withstand high wind loads and maintain structural integrity, allowing for flexible panel sizes and types without the need for expensive retooling or equipment, reducing maintenance and operational costs.
Implementation Method 1
side collectors (210) and/or the connector (100) can be ultrasonically welded together
Data Source
Figure 1~4
Figure 5~7
Figure 8~9
AI summary
In one embodiment, a connector assembly comprises: a connector; and a pair of side collectors, each comprising a connector engagement region having a size and geometry to mate with the connector so as to hold ends of two adjacent panels together; and a panel engagement region comprising a receiving area and having a size to attach onto an edge of the panel; and a clip, wherein the clip has a base that can be attached to a support, an engagement, and a stem extending therebetween, wherein the engagement has an extension projecting from a side of the engagement, wherein the panel engagement region further comprises an opening in a joint wall on a side of the panel engagement region opposite the receiving area, wherein the opening is configured to receive the extension of the engagement.