Vibration-Anchored Connector for Low-Density Core Panels
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Solution Overview
Problem
Existing methods for securing connectors to lightweight building elements, such as sandwich boards, are costly, time-consuming, and lack sufficient anchoring strength, especially when the core layer has low density, and adhesive bonds are unreliable and difficult to monitor.
Innovation Solution
A method involving pressing a connector with liquefiable thermoplastic material against the low density layer and applying mechanical vibration to penetrate and intermingle with the deformed structure, creating a strong intertwined connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive bonds are used to secure connectors to lightweight building elements, then the bonding process can be simplified, but the reliability of long-term control and detection of bond degradation is lost
Solution Approach 1:
The patent introduces a connector as an intermediary mechanical element that bridges the second object to the first object (lightweight building element). This connector provides a detectable mechanical interface that allows for long-term monitoring of bond integrity while maintaining manufacturing simplicity. The connector acts as a mediator that translates the bonding relationship into a mechanically detectable system.
2Area of stationary object
If adhesive bonds are used with rough surfaces, then more surface area is available for bonding, but the hardening process becomes slower and manufacturing costs increase
Solution Approach 1:
The patent replaces the chemical bonding mechanism (adhesive hardening) with a mechanical bonding mechanism (connector insertion and securing). This substitution eliminates the slow hardening process associated with adhesives on rough surfaces, while still achieving strong bonding through the mechanical connector that engages with the surface geometry.
3Adaptability or versatility
If connectors are added after sandwich board manufacture, then the manufacturing process is more flexible, but the core must be foam-filled subsequently which is costly and time-consuming
Solution Approach 1:
The patent incorporates the connector into the sandwich board structure during the initial manufacturing process, specifically integrating it with the core layer before final assembly. This preliminary action eliminates the need for subsequent costly and time-consuming foam-filling operations, while maintaining the flexibility to position connectors at various locations during manufacturing.
4Weight of moving object
If the core layer has low density to reduce weight, then the overall structure becomes lighter, but the anchoring strength of connectors is reduced
Solution Approach 1:
The patent applies local quality enhancement by concentrating the connector geometry and material properties specifically at the anchoring interface with the low-density core. The connector is designed with features such as expanded ends, ribs, or interlocking geometries that locally increase engagement strength with the core structure, compensating for the low overall density while maintaining lightweight 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
This method provides a quick, efficient, and cost-effective anchoring solution with substantial strength, suitable for low density layers, by using mechanical vibration to interpenetrate and deform the low density layer, ensuring a positive-fit connection.
Implementation Method 1
causing mechanical vibration to impinge on the second object to make a portion of the thermoplastic material flowable
Implementation Method 2
make a portion of the thermoplastic material flowable... causing the flowable portion to resolidify
Implementation Method 3
pressing the second object against the low density layer... a compressed structure with a first density is caused in the low density layer
Data Source
Figure 1~4
Figure 5a~5b
Figure 6~8
AI summary
According to an aspect of the invention, a method of anchoring a connector in a first object is provided, wherein the first object comprises a low density layer that comprises an arrangement of discrete elements and gas-filled (empty) spaces between the discrete elements. The method includes providing the connector, the connector having a liquefiable material that is liquefiable by mechanical vibration, such as a thermoplastic material, bringing the connector into contact with the low density layer, pressing the connector against the low density layer and coupling mechanical vibration energy into the connector to cause the connector to penetrate into the low density layer to deform the discrete elements, until a flow portion of the liquefiable material becomes flowable and is caused to interpenetrate spaces between the deformed discrete elements so that an intertwined structure of the liquefiable material and the deformed discrete elements results, and stopping the mechanical vibration energy and causing the flow portion to re-solidify to anchor the connector in the low density layer.