Snap-Fit Connector Bracket System for Modular Wall Panel Assembly

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Solution Overview

Problem

Existing modular wall and partition systems face challenges with expensive, bulky, and difficult-to-assemble connection hardware that lacks aesthetic appeal, making it hard to quickly and easily reconfigure office spaces without compromising design.

Innovation Solution

The development of a connector bracket system with angled receiving portions and a coupling connector that allows for snap-in connections between panels and wall modules, eliminating the need for posts and enabling flexible angle adjustments, thus simplifying assembly and improving aesthetics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional connection hardware is used to connect modular wall panels, then the connection strength and stability are improved, but the device complexity, cost, and difficulty of assembly increase

Engineering Contradiction:

Improveconnection strengthVSAvoidconnection hardware complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The connection system is divided into discrete modular components: connector brackets that attach to panel edges and coupling connectors that join the brackets. This segmentation allows each component to be optimized independently while maintaining overall connection strength, reducing the complexity of any single component.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Connector brackets serve as intermediary elements between the panel edges and the coupling connectors. These brackets provide standardized attachment points that simplify the connection process, reducing the overall device complexity while maintaining reliable connections through the intermediate coupling mechanism.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If traditional connection hardware is used to connect modular wall panels, then the connection strength and stability are improved, but the ease of assembly and manufacturing cost increase

Engineering Contradiction:

Improveconnection strengthVSAvoidassembly ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The coupling connector features self-aligning geometry with guiding surfaces that automatically position the connector relative to the bracket openings. This self-service mechanism eliminates the need for precise manual alignment during assembly, significantly improving ease of assembly while maintaining connection strength.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The connection system replaces complex mechanical fastening systems with a simplified snap-fit or insert-based coupling mechanism. The coupling connector can be inserted and secured through straightforward mechanical actions rather than requiring multiple fasteners, bolts, or welding operations, improving both ease of manufacture and assembly.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If traditional connection hardware is used to connect modular wall panels, then the connection strength is improved, but the aesthetic appearance deteriorates

Engineering Contradiction:

Improveconnection strengthVSAvoidaesthetic appearance

Core Design Contradiction:

ReliabilityVSShape

Solution Approach 1:

The connection hardware is extracted and positioned to be concealed from view in the final assembly. The connector brackets attach to the edges or rear surfaces of panels, and the coupling connectors join these hidden components, allowing the front surfaces of the panels to maintain clean, uninterrupted aesthetic appearances while still providing strong connections.

Inventive Principle:

Principle #2Taking out (Extraction)

4Adaptability or versatility

If modular wall panels are reconfigured to meet changing organizational needs, then the adaptability is improved, but the time required for reconfiguration increases

Engineering Contradiction:

Improvereconfiguration flexibilityVSAvoidreconfiguration time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The connection system is designed to be dynamically reconfigurable, allowing panels to be easily connected and disconnected. The coupling connectors can be quickly inserted and removed from the bracket openings, enabling rapid reconfiguration of wall layouts to meet changing organizational needs without time-consuming disassembly and reassembly processes.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The connector brackets are pre-attached to the panel edges during manufacturing, and the coupling connectors are designed with features that guide and align them during installation. This preliminary preparation and built-in alignment reduce the time required for reconfiguration by eliminating the need for on-site measurement, marking, and precise positioning operations.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS9874010B2Panel and wall module connection apparatus, methods, and systems

Publication Date: 2018.01.23 DIRTT ENVIRONMENTAL SOLUTIONS

AI summary

Implementations of the present invention relate to systems, methods, and apparatus for connecting panels, wall modules, modular walls, partitions, and combinations thereof. Particularly, one or more implementations described herein may facilitate making quick and easy connections between panels, wall modules, modular walls, partitions, and combinations thereof. Furthermore, at least one implementation may allow an installer to interconnect panels, wall modules, modular walls, partitions, while providing a pleasing aesthetic in a final structure.