Conical Resilient Locking Washer for Fragile Part Assembly
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Solution Overview
Problem
Current assembly methods for parts made from materials with little or no plastic domain, such as silicon-based materials, are expensive and prone to breakage due to the need for precise gluing and application of axial forces.
Innovation Solution
An assembly system using a conical elastic locking element made of a metal or metal alloy, such as copper or brass, that secures the part without gluing by applying an elastic peripheral force, ensuring the assembly is stable and resistant to relative rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If gluing is used to assemble silicon-based parts with metal members, then assembly precision is improved, but manufacturing cost increases and production time is lost
Solution Approach 1:
The patent replaces the chemical bonding system (gluing) with a mechanical locking system. The conical elastic locking element inserted into the conical cavity creates a mechanical interlock between the silicon-based part and metal member, eliminating the need for adhesive bonding while achieving secure assembly.
Solution Approach 2:
The patent introduces an intermediary elastic locking element as a mediator between the silicon-based part and the metal member. This locking element with conical geometry facilitates the connection by deforming elastically to engage with both components, providing a reliable mechanical bond without direct contact between the silicon and metal surfaces.
2Strength
If axial forces are applied to silicon-based parts during assembly, then assembly integrity is improved, but the parts are prone to breakage due to their material properties
Solution Approach 1:
The patent employs conical (curved) geometry for both the locking element and the cavity instead of straight cylindrical forms. This conical configuration allows gradual engagement and distribution of assembly forces along the tapered surface, reducing stress concentration and the risk of breakage during assembly while ensuring secure mechanical interlocking.
3Reliability
If conventional assembly methods are used for silicon-based parts, then material integrity is preserved, but the assembly process becomes complex and expensive
Solution Approach 1:
The patent merges the functions of connection, positioning, and force distribution into a single conical elastic locking element. This integrated component simultaneously achieves all assembly requirements through its geometric design, eliminating the need for multiple separate assembly operations or additional protective measures for the silicon-based part.
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
The system simplifies the assembly process, avoids breakage of fragile materials, and maintains structural integrity without the need for gluing or additional locking covers, allowing for secure attachment even under high stress conditions.
Implementation Method 1
a locking element (9, 109, 129, 209) made of a third material arranged to elastically attach the part (5, 105, 205) between the bearing surface (4) of the member (3, 103, 123, 203) and the locking element (9, 19, 109, 129, 209)
Data Source
Figure 1~10
Figure 3~8
Figure 11
AI summary
The invention relates to an assembly system comprising a member made of a first material having an axis and a bearing surface, the axis of the member being received in the opening of a part made of a second material having little or no plasticity. According to the invention, the assembly system comprises a locking element made of a third material arranged to elastically attach the part between the bearing surface of said member and the locking element (9, 19, 109, 129, 209), and in that the locking element (9, 19, 109, 129, 209) is a conical washer having an inner wall (10) that radially clamps the axis (2, 102, 122, 202) of said member, and a peripheral portion of the locking element that exerts an axial and elastic force perpendicular to the bearing surface of said member in order to secure the assembly of member - part - locking element.