Connector System for Structural Panels with Concealed Recess
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Solution Overview
Problem
There is a need for improved methods and connectors to securely interconnect structural insulated panels (SIPs) and sandwich panels in building construction, particularly to effectively transfer loads between panels and components while ensuring durability and aesthetic appeal.
Innovation Solution
A method and connector system that secures a connector to both the panel and structural components, utilizing load-transmissive engagement mechanisms such as bonding and protuberances to direct loading onto the panel's substrate and covering, with features like adhesive application and spacer protuberances to enhance bonding and concealment, and includes various configurations for different panel orientations and connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a connector is used to interconnect panels and structural components, then the connection strength and load-bearing capacity are improved, but the aesthetic appeal is worsened due to visible connectors
Solution Approach 1:
The connector is nested within a recess formed in the panel surface, with the connector body positioned inside the recess and only minimal portions visible or flush with the panel surface. This nesting approach maintains connection strength while significantly improving aesthetic appeal by concealing the connector within the panel structure.
Solution Approach 2:
A recess structure serves as an intermediary element between the connector and the panel surface. The recess allows the connector to be embedded within the panel rather than mounted on the surface, mediating between the structural requirement for visible connectors and the aesthetic requirement for concealed connectors.
2Shape
If the connector is embedded within the panel recess, then the aesthetic appeal is improved by concealing the connector, but the manufacturing complexity increases due to additional recess formation steps
Solution Approach 1:
The recess is formed in the panel during the panel manufacturing process itself, before the connector installation step. This preliminary formation of the recess eliminates the need for separate field construction activities to create the recess, thereby reducing overall manufacturing complexity while achieving the aesthetic benefit of concealed connectors.
Solution Approach 2:
The recess formation operation is merged with the panel manufacturing process, combining two operations (recess creation and panel production) into one integrated process. This merging reduces the total number of manufacturing steps and simplifies the overall manufacturing complexity.
3Reliability
If bonding adhesive is applied to enhance the bond between connector and panel, then the connection reliability is improved, but the manufacturing precision requirements increase for proper adhesive application
Solution Approach 1:
The recess structure serves as a cushioning or compensating feature that accommodates variations in adhesive application. By providing a confined space with defined boundaries, the recess ensures that adhesive remains contained and distributed evenly, reducing the impact of application variability and maintaining reliable bonds without requiring extreme precision.
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
The solution provides robust, load-bearing connections that resist shear, tension, and compressive loads, while maintaining aesthetic appeal by concealing the connector and enhancing the panel's structural integrity and insulation properties.
Implementation Method 1
effecting the engagement between at least one said covering and the respective portion(s) arranged to engage it comprises bonding the covering to the respective portion(s)
Data Source
AI summary
There is disclosed a method of forming a connection between a structural component and a panel, the panel comprising a substrate and a load-resistant covering over either or each side of the substrate, the method comprising securing a connector to the component and panel such that the connector engages at least one said covering and the component so as to direct, to the covering(s) engaged thereby, loading exerted by the component.