Fastener-Free Box Assembly With Interlocking Board Connections
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Solution Overview
Problem
Existing storage boxes require time-consuming and laborious assembly using fasteners, which is inconvenient for users and inefficient for manufacturers, and disassembly is equally challenging due to the need for precise mounting holes and pre-embedded fasteners.
Innovation Solution
A fastener-free box design featuring integrally formed insert-connection structures between boards, allowing for interlocking assembly without tools and enabling easy disassembly, with features like dovetail grooves and ribs for secure connections and a rotatable hinge for the cover board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fasteners and screws are used to connect boards, then the box structure is secure and stable, but the assembly process becomes time-consuming and laborious
Solution Approach 1:
The box is divided into separate board components (baseboard, side boards, cover board) that can be assembled independently through insertion connections, allowing for modular assembly without requiring pre-drilled holes or fasteners across the entire structure
Solution Approach 2:
Insertion connection structures serve as intermediary elements between adjacent boards, providing a mechanical interface that enables secure connection through simple insertion and interlocking actions, eliminating the need for traditional fasteners
2Strength
If pre-embedded fasteners are installed in mounting holes, then the connection strength is improved, but additional manufacturing processes are required reducing production efficiency
Solution Approach 1:
The insertion connection structure merges multiple functions into a single integrated component formed from the board material itself, combining the structural board with the connection feature, thereby eliminating separate fastener installation processes
Solution Approach 2:
The board material itself provides the connection functionality through integrally formed insertion structures, making the board self-sufficient for both structural and fastening purposes, eliminating the need for additional fasteners and their installation
3Manufacturing precision
If mounting holes are reserved in advance on boards, then precise assembly is enabled, but errors in hole positions prevent proper assembly
Solution Approach 1:
Instead of creating holes in boards to receive fasteners, the invention inverts the approach by forming protruding insertion structures on the boards themselves that insert into corresponding recesses, eliminating the need for precise hole alignment
4Reliability
If traditional screwed connections are used, then the box is securely fastened, but disassembly requires loosening each screw individually making it highly inconvenient
Solution Approach 1:
The insertion connection structure enables dynamic assembly and disassembly through simple insertion and extraction motions, allowing the box to be easily taken apart and reassembled without the tedious process of individual fastener manipulation
Data Source
AI summary
A fastener-free box with fast assembly comprises a baseboard, a front board, a rear board, a left board, a right board, and a cover board. An insert-connection structure that is configured to form an insert connection with a respective adjacent board is integrally formed on each of the board; and, a connection structure configured to couple with each other is integrally and individually formed on each of the cover board and the rear board. The structure of the box is simple. In addition, an interlocking structure can be formed after the box is assembled, enabling a robust box structure. Furthermore, the box is ideal for outdoor use as it is water proof.