Suction-Cup Panel Joiner for Damage-Free Countertop Alignment
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Solution Overview
Problem
The challenge lies in accurately and cost-effectively joining solid panel countertops, such as wood or granite, without damaging the surfaces during the clamping process, as existing methods are time-consuming and can mar the panels.
Innovation Solution
A panel joiner system utilizing suction cups with a moving mechanism and surface alignment module for fine adjustments, allowing for seamless and smooth transitions between panels, with mechanisms for lateral, perpendicular, and rotational movements to align edges and corners without damaging the surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional clamping methods are used to join panels, then the panels can be held together during the joining process, but the clamping can damage the panel surfaces by marring or leaving marks
Solution Approach 1:
The patent introduces registration pins as intermediary elements that mediate between the clamping mechanism and the panel surfaces. These pins contact the panels at specific locations to provide alignment and holding force, while the soft material tips of the pins prevent direct contact between hard clamping surfaces and the panel, thereby avoiding surface damage while maintaining joining strength
Solution Approach 2:
The patent employs registration pins with soft material tips (such as rubber or plastic coatings) that act as flexible protective interfaces. These soft tips conform to the panel surfaces and distribute contact pressure, preventing marring and marks while still providing sufficient friction and mechanical interlocking to hold panels together during the joining process
2Ease of operation
If registered side edges are formed on panels to simplify alignment, then the alignment process is simplified, but the cost of panel fabrication increases
Solution Approach 1:
The patent implements a self-aligning mechanism where the registration pins automatically find and engage with corresponding features on adjacent panels during the joining process. The pins are designed to insert into pre-drilled holes or engage with edge profiles, allowing panels to self-position and align without requiring precision-machined registration edges, thereby simplifying alignment while avoiding the need for expensive edge preparation
Solution Approach 2:
The patent uses pre-drilled alignment holes or pre-formed edge profiles on panels that guide the registration pins into proper position before final clamping occurs. This preliminary positioning action simplifies the alignment process during assembly, as the pins naturally follow the pre-prepared guides, eliminating the need for complex real-time adjustment or precision-machined registration surfaces
3Manufacturing precision
If manual alignment methods are used to position panels accurately, then the joining can be achieved, but the process becomes time-consuming
Solution Approach 1:
The patent replaces manual visual alignment and adjustment with a mechanical guidance system consisting of registration pins that physically constrain panel positions. The pins engage with pre-drilled holes or edge features to automatically establish precise relative positioning between panels, eliminating time-consuming manual measurement and adjustment while maintaining high positioning accuracy through mechanical interference fit
Solution Approach 2:
The patent incorporates pre-drilled alignment holes or pre-formed positioning features on panels that are created during initial panel fabrication. These pre-prepared features enable rapid insertion and engagement of registration pins during assembly, automatically establishing accurate panel positioning without requiring time-consuming manual measurement, marking, or adjustment operations
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
Enables quick, low-cost, and damage-free joining of panels, providing a seamless and aesthetically pleasing interface with precise alignment, suitable for both professional and inexperienced users.
Implementation Method 1
The panel joiner can include two sets of suction cups, with the suction cups configured to be coupled to top surfaces of the two panels by vacuum suction
Data Source
AI summary
A panel joiner system includes 2 sets of suction cups couple together through a linear guide to allow the sets of suction cups to move toward each other for joining panels along the edges. A movement mechanism is also coupled to the suction cups to convert a rotational movement to a linear movement of the suction cups. A surface alignment module is coupled to the linear guide to move between the suction cups for aligning the top surface of the panels. Compressible materials or ball bearings can be disposed between the section cups and the linear guide to allow the panel joiner to adjust the panel positions for joining.