Structural Panel Anchors for Lightweight Reconfigurable Joints

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Solution Overview

Problem

Existing building panels are either heavy and inflexible, expensive and strong, or lightweight but not strong enough to support fasteners, and existing connection methods are costly, require specific male and female panels, and damage the panels when disassembled.

Innovation Solution

A method and system for connecting building panels using anchors with troughs or slots and connectors that engage these anchors, allowing panels to be securely joined without exposing fasteners and enabling flexible panel configurations and re-sizing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If solid plywood or particle wood board panels are used, then strength is improved, but weight increases substantially

Engineering Contradiction:

Improvepanel strengthVSAvoidpanel weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent applies porous materials by using a honeycomb core structure with hexagonal cells that are lighter than solid wood while maintaining structural strength. The hollow chambers provide structural support without the full material density of solid plywood, directly resolving the contradiction between strength and weight.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent uses composite materials by combining thin plywood or particle board panels with a honeycomb core structure. This composite construction allows the panel to achieve the strength of solid wood through the geometric configuration of the honeycomb structure while maintaining the weight advantages of thinner materials.

Inventive Principle:

Principle #40Composite materials

2Weight of moving object

If hollow core panels are used, then weight is reduced, but strength decreases to the point where fasteners cannot be supported

Engineering Contradiction:

Improvepanel weightVSAvoidfastener support strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The honeycomb core structure provides a porous yet load-bearing configuration where the hexagonal cells distribute mechanical loads effectively. This allows the panel to remain lightweight while the geometric structure of the honeycomb provides sufficient strength to support fasteners, unlike simple hollow cores.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent transitions from a two-dimensional hollow space to a three-dimensional honeycomb structure with hexagonal cells. This dimensional complexity adds structural strength in multiple directions, enabling the lightweight panel to support fasteners while maintaining low weight.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Strength

If foam or paper honeycomb is added to open-core panels, then strength is improved, but adaptability decreases because panel size cannot be changed

Engineering Contradiction:

Improvepanel strengthVSAvoidpanel size adaptability

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The panel is segmented into a modular honeycomb core structure with repeating hexagonal units. This segmentation allows the core to be manufactured in standard sizes while maintaining structural integrity, and the modular nature enables flexibility in panel configuration and assembly without requiring foam or paper honeycomb that would prevent size changes.

Inventive Principle:

Principle #1Segmentation

4Strength

If male and female locking members are used to connect panels, then connection strength is improved, but device complexity increases and panel damage occurs during disassembly

Engineering Contradiction:

Improveconnection strengthVSAvoidconnection system complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges the connection function into the panel edge structure itself, using integrated locking features that are part of the panel construction rather than separate male and female components. This simplifies the connection system while maintaining strength and allows for reversible assembly without damaging the panels.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connection system is designed with universal features that allow any panel to connect to any other panel of the same type, eliminating the need for differentiated male and female components. This reduces device complexity while providing sufficient connection strength through standardized interfaces.

Inventive Principle:

Principle #6Universality (Multi-functionality)

5Strength

If rotary locks are used to connect panels, then connection strength is improved, but cost increases and installation complexity increases

Engineering Contradiction:

Improveconnection strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The locking mechanism is merged into the panel edge structure during manufacturing, eliminating the need for separate rotary lock components. This integration reduces manufacturing cost and simplifies installation while maintaining connection strength through the built-in locking features of the panel design.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11585090B2Method and system for interconnecting structural panels

Publication Date: 2023.02.21 FLEMING III JOSEPH C

AI summary

Building or structural panels may be joined, such as to form walls or floors. The panels may be connected in various orientations via one or more connectors. The connectors may mount to anchors associated with the panels. The panels may have outer skins located over an expanded core comprising a matrix of supporting elongate members and voids or openings, with the anchors located at edges of the panels.