Distribution Frame Snap-Assembly Mechanism

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Solution Overview

Problem

Existing distribution frame systems require time-consuming fasteners for installation, and there is a need for a user-friendly, low-cost production method with fewer parts that allows for easy interconnection of modules.

Innovation Solution

A distribution frame module design featuring a punch bridge, locking lever, guide hole, and connecting edge that enables snap-together assembly without tools, using sheet metal construction for low-cost production and easy alignment with standard rack boxes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If traditional screw fasteners are used to fix distribution frame modules, then the connection is reliable and secure, but the installation time is excessive and the operation is complex

Engineering Contradiction:

ImproveInstallation easeVSAvoidInstallation time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The locking lever is designed to be actuated by the user directly without requiring additional tools. The lever itself serves as both the locking mechanism and the tool for operation, allowing the module to lock and unlock through simple manual manipulation of the integrated lever component.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The connection system is divided into distinct functional elements: guide holes for alignment, punch bridges for engagement, and locking levers for securing. This segmentation allows each component to perform its specific function efficiently, with the locking lever providing rapid securement without requiring threaded fasteners.

Inventive Principle:

Principle #1Segmentation

2Reliability

If multiple separate parts are used for module connection, then the connection reliability is improved, but the production cost increases and the number of parts to manage increases

Engineering Contradiction:

ImproveConnection reliabilityVSAvoidNumber of parts

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The guide holes, punch bridges, and locking lever are integrated into a unified connection system where these elements work together as a coordinated assembly. The locking lever combines alignment guidance and securing functions in a single integrated component rather than requiring separate alignment pins and fasteners.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The locking lever serves multiple functions: it guides the modules into proper alignment through its interaction with guide holes, secures the connection through its bridging action over the punch bridge, and provides a manual actuation mechanism for both locking and unlocking. This multi-functionality reduces the total part count while maintaining connection reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Strength

If traditional fastening methods are used, then the structural strength is sufficient, but the manufacturing cost is high and production efficiency is low

Engineering Contradiction:

ImproveConnection strengthVSAvoidProduction efficiency

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The connection mechanism transitions from threaded mechanical engagement to elastic deformation-based locking. The locking lever utilizes elastic bending to engage with and lock onto the punch bridge, providing sufficient connection strength through elastic forces rather than threaded friction, which simplifies manufacturing.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The locking lever is designed as a simple elastic component that can be manufactured from standard sheet metal through conventional forming processes. Rather than requiring precision-machined threaded fasteners, the system uses simple elastic deflection elements that are inexpensive to produce in high volumes through stamping or bending operations.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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

Facilitates tool-free interconnection of distribution frame modules, reducing installation time and production costs while providing flexible modular combinations and shielding properties for optical and electrical applications.

Implementation Method 1

with the elastic properties of the locking lever, it can snap over a connecting edge of another distribution frame module, locking the units together

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentEP2889661B1Distribution frame

Publication Date: 2019.10.02 NEXANS SA

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Figure 5~6

AI summary

A distribution frame module (1) is disclosed. The distribution frame module (1) comprises a first side wall (2) configured with at least one punch bridge (8) and a locking lever (9); a bottom (3); and a second side wall (4) configured with at least one guide hole (10) and a connecting edge (11), said guide hole (10) and connecting edge (11) being configured to mate with a punch bridge (8) and a locking lever (9), respectively, on another distribution frame module (1). The distribution frame module (1) has an accommodation area for linear function inside the second side wall (4), and the distribution frame module (1) can be snapped together with another distribution frame module (1), through interaction between said guide hole (10) and connecting edge (11) and said punch bridge (8) and locking lever (9), respectively, on another distribution frame module (1). The distribution frame module (1) can be manufactured from a single piece of sheet metal.