Tool-Free Aluminum Coupling Assembly for Reliable Modular Joining
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Solution Overview
Problem
Existing aluminum assemblies require screws or adhesives for assembly, which can be frustrating for inexperienced users and may lead to improper assembly causing harm or damage, especially in limited spaces where effective storage solutions are crucial.
Innovation Solution
Aluminum members with first and second coupling elements featuring grooves and protrusions with fasteners allow for detachable coupling, enabling the construction of various forms without tools, such as a shelf using plate-shaped, cross-shaped, L-shaped, and T-shaped members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screws or adhesives are used to assemble aluminum members, then the assembly strength and reliability are improved, but the ease of operation deteriorates due to requiring tools and fasteners
Solution Approach 1:
The patent replaces the traditional mechanical fastening system (screws, bolts, adhesives) with an integrated coupling element system. The coupling elements incorporate grooves and protrusions that directly engage with each other, eliminating the need for separate fasteners. This substitution maintains assembly reliability through the interlocking mechanism while dramatically improving ease of operation by allowing tool-free assembly.
Solution Approach 2:
The patent merges the coupling function and the fastening function into a single integrated coupling element. The coupling element includes both the structural component for joining aluminum members and the grooves/protrusions for secure engagement. This merging eliminates the need for separate screws or adhesives, resolving the contradiction between reliability and ease of operation.
2Strength
If multiple fasteners are used to secure aluminum members, then the assembly strength is improved, but the device complexity increases due to multiple components
Solution Approach 1:
The patent combines multiple fastening functions into a single coupling element. Each coupling element integrates grooves for engagement and protrusions for securing, replacing what would traditionally require multiple separate fasteners. This merging maintains assembly strength while reducing device complexity by eliminating redundant components.
Solution Approach 2:
The coupling element is designed as a universal component that performs multiple functions: structural joining, mechanical engagement through grooves, and securing through protrusions. This multi-functionality allows a single component to replace multiple specialized fasteners, reducing complexity while maintaining strength.
3Ease of operation
If detachable coupling without screws is used, then the ease of operation is improved, but the reliability may deteriorate due to potential improper assembly
Solution Approach 1:
The coupling element is designed to be self-aligning and self-securing. The grooves and protrusions are configured so that proper assembly is achieved automatically when components are brought together, without requiring user skill or tools. The geometry of the coupling elements guides correct positioning and ensures reliable engagement, resolving the contradiction between ease of operation and reliability.
Data Source
AI summary
An aluminum assembly includes at least an aluminum member. Each aluminum member has a first coupling element and a second coupling element extended from two edges of the aluminum member. The first coupling element has a first groove section and a first protrusion. The first groove section has a first fastener and a second fastener. The second coupling element has a second groove section and a second protrusion. The second groove section has a third fastener and a fourth fastener. As such, the first coupling element of a first aluminum member may be detachably coupled to the second coupling element of a second aluminum member, and the second coupling element of the first aluminum member may be coupled to the first coupling element of a third aluminum member. An aluminum assembly of various forms may be constructed in this way.