Hinged Alignment Tabs for Semi-Rigid Fibrous Assembly
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Solution Overview
Problem
Aligning parts in composite structures made from semi-rigid fibrous materials is challenging due to reliance on markings, jigs, and tertiary hardware, which introduces complexity and potential human error.
Innovation Solution
The use of hinging alignment tabs cut from semi-rigid fibrous bodies that depress into mating cavities, providing multi-axes alignment and temporary attachment without additional components, using CNC equipment to create precise alignment and structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If markings, jigs and tools are used for alignment, then alignment can be achieved, but device complexity and potential human error increase
Solution Approach 1:
The alignment feature and attachment feature are merged into a single integrated component. The tab structure combines both alignment guidance and temporary attachment functions in one element, eliminating the need for separate alignment tools, markings, and tertiary hardware. This integration directly reduces device complexity while maintaining alignment precision through the physical geometry of the tab-cavity interface.
Solution Approach 2:
The alignment mechanism is self-aligning through the physical geometry of the tab and cavity features. The asymmetric shapes guide the parts into correct alignment automatically during assembly, without requiring external markings, jigs, or tools. The tab's shape and the cavity's complementary form create inherent alignment guidance that eliminates human error and reduces assembly complexity.
2Manufacturing precision
If additional alignment components are used, then alignment accuracy improves, but the number of parts and assembly steps increases
Solution Approach 1:
Multiple functions (alignment and attachment) are combined into a single tab-cavity interface, eliminating the need for separate alignment components and reducing assembly steps. The integrated design achieves alignment accuracy without additional parts while improving assembly efficiency by reducing the number of operations required.
Solution Approach 2:
The alignment features are pre-formed as integral parts of the components during manufacturing. The tab and cavity geometries are built-in during fabrication, so no additional alignment preparation or setup is needed during assembly. This preliminary action eliminates the need for external alignment tools and reduces assembly time.
3Strength
If tertiary hardware is used for fastening, then secure attachment is achieved, but device complexity and tolerance stack-up increase
Solution Approach 1:
The attachment function is merged into the tab-cavity interface itself, eliminating the need for tertiary hardware. The interlocking geometry of the tab and cavity provides secure attachment through their own structural design, reducing hardware complexity while maintaining attachment strength through the physical interference fit and mechanical interlocking.
Solution Approach 2:
The attachment function is extracted from separate tertiary hardware and integrated directly into the tab and cavity features. This extraction eliminates the need for additional fasteners, clips, or mechanical connectors, reducing device complexity while maintaining attachment strength through the inherent structural design of the integrated features.
Data Source
AI summary
Embodiments disclosed herein describe an alignment device for providing mechanical alignment between multiple semi-rigid fibrous bodies. The alignment device includes a first semi-rigid fibrous body comprising an alignment tab attached to the first semi-rigid fibrous body through a hinge; and a second semi-rigid fibrous body comprising a mating cavity cut into the second semi-rigid fibrous body, where the alignment tab is located on the first semi-rigid fibrous body and the mating cavity is located on the second semi-rigid fibrous body such that mating the alignment tab with the mating cavity aligns the first semi-rigid fibrous body with the second semi-rigid fibrous body.