Profile-Panel Thermal Interlock Assembly for Recyclable Building Elements
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Solution Overview
Problem
Existing building elements require time-consuming and accurate coupling processes using destructive means, leading to structural damage and high costs, and lack recyclability.
Innovation Solution
A building element comprising a profile and panel coupled by deforming the panel within the profile using thermoplastic materials that adapt to the profile's internal shape at elevated temperatures, forming a secure, inseparable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If destructive connecting means such as screws, rivets, or glue are used to couple the profile and panel, then the coupling provides structural connection, but the coupling process becomes time-consuming and requires accurate treatment, increasing manufacturing complexity and cost
Solution Approach 1:
The patent replaces mechanical connecting means (screws, rivets, glue) with a thermal deformation process. The panel is heated to become plastically deformable, then deformed inside the profile to create a form-fit connection. This substitutes complex mechanical assembly with a simpler thermal-forming process that achieves secure coupling without additional fastening components.
Solution Approach 2:
The patent changes the temperature parameter of the panel material during assembly. By heating the panel to an elevated temperature, the material becomes plastically deformable, allowing it to be shaped inside the profile. After cooling, the material returns to its original state with permanent deformation, creating a secure mechanical interlock. This parameter change enables simple assembly process while maintaining strong coupling.
2Strength
If screws or rivets are used to connect profile and panel, then structural connection is achieved, but structural damage occurs to the panels and profiles
Solution Approach 1:
The patent eliminates mechanical fasteners (screws, rivets) that cause puncture damage and structural weakness. Instead, the panel material itself is deformed to create the connection, distributing stresses throughout the material without creating stress concentration points. This substitution eliminates the harmful effects of hole drilling and fastener installation while maintaining connection strength.
3Reliability
If traditional coupling methods with multiple components are used, then secure connection is achieved, but the building element cannot be easily disassembled for recycling
Solution Approach 1:
The patent enables complete recyclability by allowing the panel and profile to be separated after use. The thermal deformation connection, while secure during service, can be reversed by reheating the panel material to its plastically deformable state. This allows the panel to be removed from the profile, enabling material recovery and reuse, thus resolving the contradiction between connection reliability and recyclability.
4Strength
If conventional materials are used for panel and profile, then structural strength is achieved, but the weight is high, reducing transport efficiency
Solution Approach 1:
The patent employs composite construction where a thermoplastic panel is deformed inside a profile structure. This composite arrangement creates a synergistic effect where the panel provides surface coverage and the profile provides structural support. The thermoplastic material itself has favorable strength-to-weight characteristics, and the integrated design eliminates the need for heavy fastening components, achieving high structural strength with reduced overall weight.
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
Facilitates quick, automated assembly with high strength and stiffness, enabling easy disassembly for recycling and reducing material weight, enhancing transport efficiency.
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
Implementation Method 2
the panel material from being removed from the profile when cooled to operating temperature
Data Source
AI summary
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.