Coupling Device for Frame Bars Using Leaf Spring Mechanism
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Solution Overview
Problem
Existing coupling devices for connecting bars in support frames of sanitary appliances within wall systems are complex, non-versatile, require long assembly times, and lack ergonomic design, often necessitating multiple operators and imprecise adjustments.
Innovation Solution
A coupling device featuring profiled tubular bars with internal channels and a mechanism comprising a support body, leaf spring, and control member, allowing for easy, quick, and secure 90° connection of bars with adjustable alignment and ergonomic operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If known coupling devices are used to connect bars in support frames, then the connection is achieved, but the assembly process becomes complex and requires long assembly times
Solution Approach 1:
The coupling device is divided into distinct functional segments: a connection body with internal cavity for receiving bar ends, and separate coupling elements that engage with the bars. This segmentation allows for simplified manufacturing and rapid assembly while maintaining structural integrity.
Solution Approach 2:
The coupling device employs a nested structure where the connection body contains internal cavities that receive bar ends, and coupling elements are positioned within these cavities. This nesting reduces the overall number of external components and simplifies the assembly process.
2Adaptability or versatility
If known coupling devices are used, then bar connection is possible, but the number of parts increases and versatility decreases
Solution Approach 1:
The coupling device is designed as a universal connector that can join bars at various angles (90°, 180°, and other configurations) using a single standardized component design. The internal cavity and coupling elements can accommodate different bar orientations and positions, eliminating the need for multiple specialized connectors.
Solution Approach 2:
Multiple functional features are merged into a single coupling device body: the connection cavity, the coupling elements, and the alignment features are integrated into one component. This reduces the total number of parts while maintaining the ability to perform multiple connection functions.
3Ease of operation
If known coupling devices are used, then bar connection is achieved, but assembly operations become difficult and may require tools
Solution Approach 1:
The coupling elements are pre-positioned within the connection body cavity during manufacturing, and the bar ends are designed with features that guide them into the correct position. This preliminary preparation eliminates the need for complex alignment operations and tool use during assembly.
Solution Approach 2:
The coupling device incorporates movable coupling elements that can shift position to accommodate slight variations in bar alignment. This dynamic adjustment capability allows for easy manual assembly without requiring precise pre-alignment or specialized tools.
4Manufacturing precision
If known coupling devices are used, then bar connection is possible, but precise adjustment of distances and clearances cannot be achieved
Solution Approach 1:
The coupling device features adjustable coupling elements that can be positioned at multiple discrete locations along the connection body. This dynamic adjustability allows for precise control of bar spacing and clearance while maintaining a relatively simple structure through standardized adjustment positions.
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 rapid, safe, and precise assembly of support frames with improved ergonomics, allowing single-operator operation and flexible adjustments without tools, facilitating the creation of modular support frames for sanitary appliances.
Implementation Method 1
a fastening portion (16), apt to hook on a lateral wall (8) of a second bar (2)
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A coupling device (1) for connecting two bars (2) of a frame extends along an axis (X) between two axial ends (13, 14), respectively provided with an insert portion (15), insertable inside a first bar (2); and with a fastening portion (16), adapted to hook on a lateral wall (8) of a second bar (2), to be joined perpendicularly to the first bar (2); the coupling device (1) comprises a support body (17); a leaf spring (18) elastically deformable and supported by the support body (17); and a control member (19) rotating about the axis (X) and acting on the leaf spring (18) via a cam (59); the rotation of the cam (59) elastically pushes the leaf spring (18) so as to move in opposite directions respective end portions (51, 52) of the leaf spring (18) for blocking the insert portion (15) inside the first bar (2), and for hooking the second bar (2).