Blow-Molded Tube Coupling Structure for Load-Bearing Assembly
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Solution Overview
Problem
The integration of a strong and stable coupling system into blow-molded tubes is challenging due to the limitations of the blow-molding process, which only allows detailed features on the outer surface, leading to inadequate load-bearing ability and coupling permanence, preventing their use in applications requiring structural strength.
Innovation Solution
A coupling system featuring a male element with tracks and hooks engaging a female element's grooves and flange, creating a tight interference fit that prevents bending motion and supports substantial vertical loads, allowing for easy assembly and secure connection of blow-molded tubes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate pieces are used to connect multiple tubes, then assembly is simplified, but manufacturing complexity and cost increase, and aesthetics are diminished
Solution Approach 1:
The coupling system is merged directly into the tube structure during the blow-molding process. The male element is formed as an integral part of one tube while the female element is formed as an integral part of another tube, eliminating separate coupling components. This integration maintains manufacturing simplicity while achieving strong, permanent connections between tubes.
2Device complexity
If integrated coupling systems are molded into blow-molded tubes, then manufacturing complexity is reduced, but load bearing ability and coupling permanence are insufficient
Solution Approach 1:
The coupling system is segmented into distinct functional elements: the male element with protruding features (tracks and hooks) and the female element with corresponding recesses (grooves and flange). This segmentation allows each element to be optimized for its specific function while maintaining integration within the blow-molding process, achieving both manufacturing simplicity and structural strength.
Solution Approach 2:
The coupling system employs asymmetric geometry with the male element featuring tracks and hooks that engage with corresponding grooves and flange features on the female element. This asymmetric design creates a permanent, load-bearing connection that prevents separation while maintaining ease of assembly through directional insertion.
3Reliability
If detailed features are added to the outer surface of tubes, then coupling functionality is improved, but manufacturing capability is limited by blow-molding constraints
Solution Approach 1:
The coupling features (male and female elements with tracks, hooks, grooves, and flange) are pre-formed as integral parts of the tubes during the blow-molding process itself. This preliminary action eliminates the need for post-molding operations or separate assembly steps, achieving permanent couplings while maintaining manufacturing simplicity within blow-molding capabilities.
Data Source
AI summary
A support post includes a first tube with a first support face at its end and at least one groove in the first support face. The support post further includes a second tube with a barrel at its end having a diameter smaller than the first tube and dimensionally matched to a hole in the first support face. The second tube further includes at least one track on the barrel that engages the at least one groove and at least one hook on the barrel that engages a flange in the interior of the first tube. The second tube further includes a second support face at an end of the barrel that engages the first support face. The components are dimensioned so as to form a tight fit between the first and second support faces and the hook and flange to prevent bending motion between the first and second tubes.