Resilient Metal Connector for Panel Mounting
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Solution Overview
Problem
Existing push-through snap lock connection systems, particularly those used for mounting panels to substrates, face issues with durability, fire resistance, and tolerance for misalignment and thermal expansion, leading to potential noise and safety hazards.
Innovation Solution
A connector assembly comprising a metal base with a housing cavity, a resilient interface element, and a metal clip that allows for flexible engagement of a male connector, providing fire resistance, noise reduction, and accommodating minor misalignments through the use of a resilient interface element and a metal clip that maintains connection even under heat stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal connectors are used to improve strength and fire resistance, then durability and fire resistance are improved, but tolerance for misalignment and thermal expansion is reduced
Solution Approach 1:
The connector assembly uses different materials for different parts: metal for the base and clip (providing strength and fire resistance) and resilient material for the interface element (providing tolerance for misalignment). This local differentiation of material properties resolves the contradiction between needing rigid metal for fire resistance and flexible tolerance for misalignment.
Solution Approach 2:
The connector assembly combines metal components (base and clip) with a resilient interface element made of deformable material. This composite structure integrates the fire resistance and strength of metal with the misalignment tolerance of resilient materials, resolving the technical contradiction.
2Strength
If rigid metal connectors are used to provide strength, then load-bearing capacity is improved, but noise from thermal expansion misalignment increases
Solution Approach 1:
The resilient interface element is strategically placed at the interface between metal components to locally absorb thermal expansion movements, preventing the transmission of noise while maintaining the overall structural strength provided by the metal base and clip.
Solution Approach 2:
The resilient interface element acts as an intermediary between the rigid metal base and clip, absorbing thermal expansion misalignment and preventing direct contact that would generate noise, while still allowing the metal components to provide their full load-bearing capacity.
3Ease of manufacture
If plastic connectors are used to reduce cost, then manufacturing expense is reduced, but fire resistance and durability are compromised
Solution Approach 1:
The resilient interface element uses plastic or rubber material only where flexibility and cost-effectiveness are needed, while the critical fire-resistant and load-bearing portions (base and clip) are made of metal. This localized use of materials achieves both cost reduction and fire resistance.
Solution Approach 2:
The connector assembly uses a composite construction with metal components for fire resistance and structural integrity, and resilient material for the interface element. This composite approach provides fire resistance where needed while keeping manufacturing costs lower than fully metal construction.
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 enhances the durability and fire resistance of the connector assembly, reduces noise from misalignment, and ensures secure panel attachment even under thermal stress, preventing panel detachment during fires or other heat-induced failures.
Implementation Method 1
Variations in ambient temperature can result in the expansion and contraction of the materials of both a panel and a mounting substrate
Implementation Method 2
metal connectors are by their very nature rigid and have limited tolerances for inaccuracies or misalignment in the placement of components
Data Source
Figure 1
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Figure 3~4
AI summary
A connector assembly Includes: a metal base which defines a housing cavity arranged to receive the end of a male connector; a resilient interface element located inside the housing cavity; and a metal clip located inside the housing cavity by the resilient interface element; the metal clip being arranged to engage removably with the end of the male connector inserted into the housing cavity to connect the metal base to the male connector.