Structural Panel Connector Mounting Without Layer Separation

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Solution Overview

Problem

Forming slots in panels for connector mounts can lead to peeling or separation of panel layers, reducing structural integrity and longevity.

Innovation Solution

A method involving the formation of a bore and a mounting channel in the panel, allowing a bracket with washers to be securely positioned within the slot, providing a stable mounting point for panel connectors without extending beyond the panel edge, thus maintaining panel integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If slots are formed in panels for connector mounts, then connector mounting is enabled, but panel layer peeling or separation occurs reducing structural integrity

Engineering Contradiction:

Improveconnector mounting capabilityVSAvoidpanel structural integrity

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The slot formation process is segmented into two distinct operations: first forming a bore through the panel, then forming a mounting channel within the bore. This segmentation allows the connector mount to be positioned without compromising panel integrity, as the mounting channel is contained within the bore rather than extending through the entire panel thickness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mounting channel acts as an intermediary structure between the bore and the connector mount. It provides a controlled space for positioning the connector mount while preventing direct exposure of the mount to the panel exterior, thereby maintaining panel structural integrity while enabling connector mounting.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If connector mounts extend beyond panel edge, then connector positioning is simplified, but panel structural integrity is compromised

Engineering Contradiction:

Improveconnector positioningVSAvoidpanel structural integrity

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The mounting channel is nested within the bore, creating a hierarchical structure where the mounting channel is contained within the larger bore volume. This nesting allows the connector mount to be positioned within the panel thickness without extending beyond the panel edge, maintaining structural integrity while enabling connector positioning.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The solution moves the connector mount positioning from a two-dimensional surface operation to a three-dimensional volumetric operation within the bore. By utilizing the depth dimension of the panel, the mounting channel can be formed without extending beyond the panel edge, maintaining structural integrity while enabling connector positioning.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS11680592B2Method and system for interconnecting structural panels

Publication Date: 2023.06.20 FLEMING III JOSEPH C

AI summary

A panel may be configured with panel mounts by forming a panel connector accepting slot in the panel and then locating connector mounts in the slot. In another embodiment, a panel may be configured with panel connector mounts by milling a panel to leave areas of panel material which form the mounts and milling the panel behind to connector mounts to define areas for accepting portions of the panel connector. Panels having the defined connector mounts may be connected by one or more panel connectors which engage the connector mounts.