Structural Component Interconnect Assembly with Flange Slots
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Solution Overview
Problem
The existing methods for securing structural components, such as doors and door frames, require costly labor and materials for forming threaded holes and do not entirely eliminate movement between components, with jigs providing no additional structural support after assembly.
Innovation Solution
A structural component interconnect assembly using a connection component with flanges that create an interference fit by engaging slots on the components, eliminating the need for screws and providing additional structural support through friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screws are used to secure structural components, then the components can be connected together, but threaded holes must be formed in each component which increases labor and material expense
Solution Approach 1:
The patent extracts the threading operation from the assembly process by using smooth flanges that engage with slots, eliminating the need to form threaded holes in the structural components. This reduces manufacturing complexity and cost while maintaining connection strength through the flange-slot interference fit mechanism.
Solution Approach 2:
Instead of forming threads in the structural components to receive fasteners, the patent inverts the approach by providing pre-formed flanges on the connection component that engage with slots in the structural components. This reversal eliminates the need for threaded holes in the main components.
2Ease of operation
If screws are used to secure components, then the components can be held together, but movement between components is not entirely eliminated
Solution Approach 1:
The patent changes the geometric parameters of the connection interface by using slots with specific width tolerances that create an interference fit with the flanges. This interference fit eliminates play and movement between components while maintaining ease of assembly through the straightforward insertion process.
3Manufacturing precision
If jigs are used to secure components during assembly, then the desired configuration can be maintained, but the jigs provide no additional structural support after removal
Solution Approach 1:
The patent merges the alignment function traditionally performed by jigs with the permanent connection function. The slots in the structural components serve as both alignment guides during assembly and as permanent connection elements that provide ongoing structural support, eliminating the need for separate jigs.
Solution Approach 2:
The slots in the structural components serve multiple functions: they guide the flanges during assembly (alignment function), maintain the desired configuration (positioning function), and provide permanent structural support (connection function). This multi-functionality replaces the single-function jig.
4Strength
If threaded holes are formed in components, then screws can be inserted to secure components, but this is a two-step process of drilling and tapping that increases labor
Solution Approach 1:
The patent extracts the threading operation from the assembly process entirely. By using smooth flanges that engage with pre-formed slots, the complex two-step process of drilling and tapping is replaced with a single insertion operation, significantly improving assembly speed and productivity.
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
This solution reduces material and labor costs, minimizes incidental movement between components, and enhances structural integrity by eliminating the need for screws and providing additional support through the interference fit.
Implementation Method 1
securing the first component to the second component via friction between the first component and the connection component
Data Source
AI summary
A structural component interconnect assembly includes a first component adapted for interconnection with a second component. A connection component is adapted for securing the first component and the second component together in a secured interconnection. The connection component includes at least two flanges spaced from each other by a first distance. The first component includes a mating surface having at least two slots formed therein and spaced one from another by the first distance. The second component includes a first surface and a second surface spaced one from the other by a distance on the order of the first distance. Engagement of the at least two flanges, via the at least two slots, with the first surface and the second surface secures the first component to the second component.