Thermoplastic Panel-to-Profile Interlock for Fast Building Assembly

Solution Overview

Problem

Existing building elements require time-consuming and accurate coupling methods using screws or other destructive means, leading to structural damage and high costs.

Innovation Solution

A building element comprising a profile and panel coupled through deformation of the panel within the profile, utilizing thermoplastic materials that adapt to an internal shape at elevated temperatures, creating a secure and inseparable connection without the need for additional fastening means.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If screws or other destructive connecting means are used to couple the profile and panel, then a stable and secure coupling is obtained, but the coupling takes a lot of time and requires accurate treatment, leading to structural damage and high costs

Engineering Contradiction:

Improvecoupling stabilityVSAvoidcoupling time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces the mechanical fastening system (screws, rivets) with a thermal deformation system. The panel is heated to become plastically deformable, then forced into the profile's interior space where it cools and solidifies, creating a mechanical interlock without any fastening components. This substitution eliminates the time-consuming operations of drilling, fastening, and sealing while maintaining coupling reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes parameter changes by heating the panel to its plastic deformation temperature range, forcing it into the desired shape within the profile, and then allowing it to cool and solidify. This temperature parameter change enables the panel to transition from a rigid state through a deformable state to a locked-in state, achieving secure coupling without mechanical fasteners.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If screws or other destructive connecting means are used to couple the profile and panel, then a stable and secure coupling is obtained, but structural damage occurs to the panels and profiles

Engineering Contradiction:

Improvecoupling stabilityVSAvoidstructural damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the mechanical fastening system (screws, rivets) with a thermal deformation system. The panel is heated to become plastically deformable, then forced into the profile's interior space where it cools and solidifies, creating a mechanical interlock without any fastening components. This substitution eliminates the time-consuming operations of drilling, fastening, and sealing while maintaining coupling reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces thermal energy as an intermediary to facilitate the coupling process. By heating the panel, the material becomes plastically deformable, allowing it to be shaped and forced into the profile's interior space. The thermal intermediary enables the panel to transition through a deformable state, achieving secure coupling without mechanical penetration or damage.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If conventional coupling methods are used, then secure connection is achieved, but the process is expensive and time-consuming

Engineering Contradiction:

Improveconnection securityVSAvoidmanufacturing speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces the mechanical fastening system (screws, rivets) with a thermal deformation system. The panel is heated to become plastically deformable, then forced into the profile's interior space where it cools and solidifies, creating a mechanical interlock without any fastening components. This substitution eliminates the time-consuming operations of drilling, fastening, and sealing while maintaining coupling reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent applies preliminary action by pre-heating the panel to its plastic deformation temperature before the coupling operation. This preliminary thermal treatment prepares the material in advance, allowing it to be easily deformed and forced into the profile's interior space. The pre-heating step enables subsequent rapid shaping and locking without requiring complex real-time adjustments during assembly.

Inventive Principle:

Principle #10Preliminary action

4Weight of moving object

If thermoplastic material is used in the panel, then low weight is obtained with high stiffness and strength, but additional heating equipment is required for coupling

Engineering Contradiction:

Improvebuilding element weightVSAvoidcoupling equipment

Core Design Contradiction:

Weight of moving objectVSDevice complexity

Solution Approach 1:

The patent utilizes parameter changes by heating the panel to its plastic deformation temperature range, forcing it into the desired shape within the profile, and then allowing it to cool and solidify. This temperature parameter change enables the panel to transition from a rigid state through a deformable state to a locked-in state, achieving secure coupling without mechanical fasteners.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite materials by combining the thermoplastic panel with the profile structure. The thermoplastic material provides weight reduction while maintaining stiffness and strength, and its ability to undergo plastic deformation allows it to be integrated with the profile through thermal processing, creating a unified composite building element.

Inventive Principle:

Principle #40Composite materials

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

Enables quick, automated, and secure coupling with enhanced stiffness and strength, facilitating recyclability and weight reduction while increasing loading capacity, particularly beneficial for transportation.

Implementation Method 1

a thermoplastic material can be used in the panel, which can be deformed at a temperature used during coupling, which is increased relative to a temperature of use, so that it adapts to an internal shape present in the profile

Methodology Applied

Scientific EffectThermoplastic deformation: Phase Change

Implementation Method 2

the panel will partly settle in the space between the form element and the inner wall during the deformation

Methodology Applied

Scientific EffectMaterial flow: Viscoelasticity

Data Source

PatentEP4273342A1A building element, a method for the manufacture thereof, a profile and a combination of a profile and a panel

Publication Date: 2023.11.08 D73 BV

Figure 1~8
Figure 9~11

AI summary

The present invention relates to a building element, comprising a profile and a panel, characterized in that the profile and the panel are mutually coupled by means of a deformation of the panel inside the profile. The profile preferably comprises a housing with an inner wall and an internal space defined within the inner wall and at least one access opening in the inner wall providing access to the inner space, wherein in the inner space at least a part of a form element is arranged, which form element is coupled to the inner wall on a side remote from the access opening, and wherein a thickness of the form element near the coupling to the inner wall is smaller than at a position between the coupling to the inner wall and the access opening. The invention also relates to a method for manufacturing same, to a combination of a panel and a profile as well as to the profile.