Panel Connecting Element for Flush Zero-Joint Composite Coupling
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Solution Overview
Problem
Existing connecting solutions for layered composite panels in vehicles fail to effectively align and join these panels laterally without visible joints, gaps, or overhangs, compromising the aesthetic appeal and structural integrity.
Innovation Solution
A connecting element with tabs and a coupling element that mechanically aligns edge-side projections of the panels, using a two-part design with sub-elements that pivot to form a zero joint, ensuring flush alignment and secure coupling through adhesive bonding and latching connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If typical separation profiles are used to join layered composite panels, then the panels can be laterally joined, but visible joints and gaps appear that compromise aesthetic appeal
Solution Approach 1:
The connecting element acts as an intermediary component that mediates between two layered composite panels. It features a coupling element that receives edge-side projections from both panels and tabs that connect to the rear outer surfaces, creating a zero joint appearance from the front while providing structural connection from the back.
Solution Approach 2:
The solution moves the connection mechanism from the visible front dimension to the hidden rear dimension. The coupling element handles the edge-side projections at the front to create flush alignment, while the tabs extend to the rear outer surfaces for mechanical coupling, effectively hiding the complex joint structure in the background dimension.
2Manufacturing precision
If panels are joined with visible separation profiles, then structural connection is achieved, but flush alignment and gap-free joint are not achieved
Solution Approach 1:
The connecting element has different functional zones with specialized geometries: the coupling element features a reception geometry tailored to match the edge-side projections for precise alignment, while the tabs have connection geometries optimized for attaching to rear outer surfaces. Each local region is designed with specific quality characteristics to achieve overall flush alignment.
3Reliability
If a simple connection method is used, then manufacturing is easier, but reliable mechanical coupling of edge-side projections is not achieved
Solution Approach 1:
The edge-side projections of the panels are nested within the reception geometry of the coupling element. This nesting arrangement ensures that the projections are securely received and positioned, providing reliable mechanical coupling while maintaining flush alignment of the panel surfaces.
Data Source
AI summary
The invention relates to a connecting element for mechanically coupling components. The connecting element comprising a first tab configured to mechanically couple a rear outer surface of a first component to the connecting element and a second tab is configured to mechanically couple a rear outer surface of a second component to the connecting element. The coupling element is mechanically coupled to the first tab and the second tab, and the first component and the second component each have an edge-side projection. The coupling element is configured to mechanically couple the first edge-side projection of the first component and the second edge-side projection of the second component to the coupling element such that an end face of the first edge-side projection and an end face of the second edge-side projection are arranged adjacent to one another on a front-side outer surface of the edge-side projections.