Panel Assembly Inserts for Reversible Composite Joining
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Solution Overview
Problem
Existing methods for assembling composite panels are restrictive, making disassembly difficult, leading to potential damage and limiting the ability to apply decorative finishes before assembly, while also increasing weight and manufacturing complexity.
Innovation Solution
A panel assembly system using elongated and fastening inserts that allow for easy assembly and disassembly, reducing weight and aesthetic issues, featuring inserts that are removably coupled via fasteners, enabling panels to be disassembled without damage and allowing for pre-assembly finishing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional tab and slot arrangement or fasteners are used to assemble composite panels, then the panels can be coupled together, but disassembly becomes difficult and may cause damage to the components
Solution Approach 1:
The fastening system is divided into separate components: a fastener with a head and a corresponding recess in the panel. This segmentation allows the fastener to be inserted and secured without permanently damaging the panel, enabling easy removal and reinstallation while maintaining coupling strength during assembly.
Solution Approach 2:
The fastener acts as an intermediary element between panels, providing a reversible coupling mechanism. The fastener can be inserted through one panel and secured by the recess in the other panel, creating a strong but reversible connection that avoids direct permanent attachment between panels.
2Strength
If heavy fastening hardware is used to assemble panels, then the coupling strength is sufficient, but the overall weight of the structure increases
Solution Approach 1:
The fastener is designed as a simple, lightweight component that can be easily manufactured and replaced if needed. Rather than using heavy permanent fastening hardware, the system employs simple fasteners that provide sufficient coupling strength while minimizing weight addition to the overall structure.
3Ease of manufacture
If panels are assembled before applying decorative finishes, then the assembly process is simplified, but the panels cannot be disassembled for finishing without damage
Solution Approach 1:
The fastening system transitions from a static permanent connection to a dynamic reversible connection. The fastener can be easily inserted and removed, allowing panels to be assembled in various sequences - either before or after applying decorative finishes - without risk of damage during disassembly or reassembly.
4Strength
If traditional fastening methods are used, then the panels are securely coupled, but the hardware adds complexity to manufacturing and assembly fixtures
Solution Approach 1:
The fastener system is designed to be self-aligning and self-securing. The fastener head fits into the corresponding recess, providing automatic alignment and secure attachment without requiring complex fixtures or specialized tools for manufacturing or assembly. The simple geometry of the fastener and recess enables straightforward production processes.
Data Source
AI summary
A panel assembly can include a first panel having a peripheral side located between an upper and a lower surface of the first panel and a first opening. The panel assembly can also include a second panel having a second opening. An elongated insert can be coupled to the first panel, the elongated insert having a coupling side, where the first opening of the first panel can be sized and shaped to coupleably receive the elongated insert such that the coupling side is positioned proximal to the peripheral side. The panel assembly can also include a fastening insert, where the second opening of the second panel can be sized and shaped to receive the fastening insert. A fastener can be received by the fastening insert and the elongated insert, the fastener coupling the first panel to the second panel via the fastening insert and the elongated insert. Related methods for assembling the panel assembly are also provided.