Structural Panel Chase Connection Pre-Manufacturing

Solution Overview

Problem

Existing methods for manufacturing structural panels require post-manufacture drilling and modification to create connection points and chases for utilities, leading to inefficiencies and potential inaccuracies.

Innovation Solution

The method involves pre-manufacturing high precision stiles and channels in building materials before assembly, allowing for pre-installed chase cavities and connection points, eliminating the need for post-manufacture modifications and enhancing precision.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If post-manufacture drilling and modification is used to create connection points and chases, then the building material can be manufactured first and modified later, but the precision and accuracy of connection points deteriorate and additional energy consumption occurs

Engineering Contradiction:

Improveprecision of connection pointsVSAvoidenergy consumption

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The patent applies preliminary action by creating chase cavities and connection points during the initial panel manufacturing process rather than modifying panels after manufacture. The chase cavities are formed by positioning channels between panels during assembly, and connection points are created by drilling through multiple layers simultaneously during the manufacturing process, ensuring high precision without post-manufacture modifications

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent merges the manufacturing of connection points and chase cavities with the panel assembly process itself. Multiple operations (drilling through panels, creating chase cavities, forming connection points) are combined into a single manufacturing step, eliminating the need for separate post-manufacture modification operations and reducing total energy consumption

Inventive Principle:

Principle #5Merging (Combining)

2Productivity

If post-manufacture drilling and modification is used to create connection points and chases, then the building material can be manufactured first and modified later, but the manufacturing time and productivity deteriorate

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidmanufacturing time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent applies preliminary action by creating chase cavities and connection points during the initial panel manufacturing process rather than modifying panels after manufacture. This eliminates subsequent modification steps and reduces total manufacturing time

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent merges the manufacturing of connection points and chase cavities with the panel assembly process itself. Multiple operations are combined into a single manufacturing step, eliminating the need for separate post-manufacture modification operations and improving overall productivity

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If CNC routing is used to modify building material after manufacture, then connection points can be created, but the precision is limited compared to pre-manufacturing methods

Engineering Contradiction:

Improveprecision of chase cavitiesVSAvoidease of creating connection points

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by creating chase cavities and connection points during the initial panel manufacturing process. The chase cavities are formed by positioning channels between panels during assembly, ensuring high precision without requiring subsequent CNC routing operations

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent merges the manufacturing of connection points and chase cavities with the panel assembly process itself. Multiple operations are combined into a single manufacturing step, eliminating the need for separate post-manufacture modification operations and improving overall productivity

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11268278B2Structural panel chase connection manufacture method

Publication Date: 2022.03.08 SING PETER

AI summary

Structural Panel Chase Connection Manufacture Methods are the embedded frame solution to the problems associated with providing access for services, such as plumbing or electrical chases with high precision and accuracy. Connecting two or more panels in any direction using the embedded frame method becomes easy yet incredibly strong without requiring special tools for assembly or disassembly, so that components can be flat packed and stored when not in use.Flexible and variable these Structural Panel Chase Connection Manufacture Methods can accommodate a wide variety of dimensional configuration, not limited to only panel, post and beam configurations and can be manufactured using any available flat building materials.