Segmented Leveling Spacer System for Panel Alignment
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Solution Overview
Problem
Conventional spacer systems are inefficient for adjusting multiple panel members simultaneously, as they can only adjust two or four members at a time, require complex operations, and have high molding costs due to intricate designs.
Innovation Solution
A leveling spacer system comprising circular bases with rectangular necks and grooves, rectangular plates with notches, and knobs with threaded connections, allowing for flexible adjustment of gaps between panel members, enabling efficient leveling of multiple panels with reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional spacers with multiple protrusions and breakable portions are used, then the spacer can adjust panel members, but it can only adjust two or four panel members at one time which takes time
Solution Approach 1:
The spacer is divided into multiple independent adjustable units, each capable of adjusting panel members independently. The base has multiple protrusions extending in different directions, and each protrusion can be adjusted independently through its own knob, allowing simultaneous adjustment of multiple panel members
Solution Approach 2:
The spacer design allows a single spacer to perform multiple adjustment functions by incorporating multiple protrusions and knobs. Each knob can adjust different panel members, making the spacer universal for adjusting various numbers of panel members (2, 4, or more) simultaneously, reducing the need for multiple different spacer types
2Adaptability or versatility
If conventional spacers with limited adjustment range are used, then the structure is simple, but the gaps between panel members can only be adjusted within a limited range
Solution Approach 1:
The spacer incorporates dynamic adjustment capabilities through threaded portions and knobs that allow continuous modification of protrusion positions. The breakable portions enable the structure to transition from an adjustable state to a fixed state, providing both adaptability during installation and stability after adjustment
Solution Approach 2:
The spacer allows changing the gap adjustment range by modifying the extension length and positioning of multiple protrusions. Each protrusion can be independently adjusted to different positions along its axis, enabling the spacer to adapt to various gap requirements without changing the overall spacer structure
3Reliability
If spacers with complicated shapes are used, then the leveling function is achieved, but the molding expenses are high
Solution Approach 1:
The spacer is segmented into simple geometric components (base, protrusions, knobs) that can be molded separately using standard molds. This segmentation allows each component to have a simple shape that is easy and cost-effective to manufacture, while the assembly of these simple components achieves the complex leveling function
Solution Approach 2:
Multiple functional elements are merged into a single integrated spacer structure. The base, multiple protrusions, threaded portions, and knobs are combined into one piece that performs leveling, spacing, and adjustment functions simultaneously, reducing the need for multiple separate components and lowering overall manufacturing costs
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 system allows for efficient leveling of multiple panel members with reduced operational time and material consumption, as it can adjust larger numbers of panels and simplify the adjustment process, while maintaining cost-effectiveness.
Implementation Method 1
Each neck has a first threaded portion connected to the top thereof. The first threaded portion is threadedly connected to the second threaded portion
Implementation Method 2
Each knob has a pressing portion which has a flat underside. The first threaded portion is threadedly connected to the second threaded portion to press the pressing portion onto the plate which presses on the panel members
Data Source
AI summary
A leveling spacer system includes a multiple plates, multiple spacers and multiple knobs. The spacers are threadedly connected to the knobs to clamp the panel members, and the plates are used to connect the spacers and the knobs together with so as to clamp more panel members. The plates and the knobs are located on the top of the panel members, and the spacers are located at the underside of the panel members. When the panel members are leveled, the knobs are removed, and the necks on the spacers are broken to finish the leveling of the panel members.