Interlocking Orthopedic Assembly with Third-Component Constraint
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing assembly technologies face challenges such as increased time, cost, and bulk due to the use of fasteners, difficulty in removing components, cumbersome handling of materials, and extensive post-processing, particularly in orthopedic devices where customization and ease of disassembly are necessary.
Innovation Solution
An assembly comprising interlocking profiles between components, where a third component maintains the interlocked structure, potentially formed from different materials, and can be either permanently or removably secured, with additional components providing protection and customization, such as overmolding with polymeric materials and flexible plastics to enhance structural integrity and user-friendliness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fasteners are used to secure components, then components can be firmly attached, but manufacturing time, cost, and bulk increase
Solution Approach 1:
The patent merges the attachment function directly into the component structures themselves through interlocking profiles (e.g., male and female engagement features, snap-fit mechanisms). This eliminates the need for separate fasteners and reduces manufacturing steps by combining the structural and fastening functions into a single integrated design.
Solution Approach 2:
The patent extracts the fastening function from separate fastener components and integrates it directly into the component structures. The interlocking profiles are built into the components themselves, removing the need for additional fastening elements and simplifying the assembly process.
2Strength
If fasteners are used to secure components, then components can be firmly attached, but assembly bulk and weight increase
Solution Approach 1:
The attachment function is merged into the component structures themselves through interlocking profiles. This integration eliminates separate fastener components, thereby reducing the overall weight and bulk of the assembly while maintaining the necessary attachment strength.
3Strength
If components are permanently secured, then structural integrity is maintained, but disassembly becomes difficult
Solution Approach 1:
The patent employs reversible interlocking mechanisms such as snap-fit profiles, bayonet mounts, or threaded engagements that can be easily assembled and disassembled. These dynamic connection methods allow the assembly to transition between secured and separated states, enabling both strong attachment during use and easy disassembly for maintenance or customization.
Solution Approach 2:
The patent segments the assembly into modular components with standardized interlocking interfaces. This segmentation allows individual components to be easily separated and reattached, maintaining structural integrity during use while enabling simple disassembly when needed.
4Adaptability or versatility
If uncured resin impregnated fiber is used for customization, then material flexibility is improved, but handling becomes messy and cumbersome
Solution Approach 1:
The patent applies a protective coating or release agent to the resin impregnated fiber components before customization operations. This preliminary action prevents the resin from adhering to tools, surfaces, or skin during handling and shaping, making the customization process cleaner and easier to control.
Solution Approach 2:
The patent introduces a release agent or protective film as an intermediary between the uncured resin and the handler's skin or tools. This intermediary layer allows for easy manipulation and shaping of the resin components without direct contact, reducing mess and improving handling ease during customization.
5Manufacturing precision
If extensive post-processing is performed, then finished surface quality is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent incorporates surface finish features directly into the molding or forming process of the components. By preliminary shaping the surfaces to their final configuration during primary manufacturing, the need for extensive post-processing operations is eliminated, reducing both complexity and cost while maintaining high surface quality.
Solution Approach 2:
The patent merges the surface finishing function into the primary manufacturing process through techniques such as injection molding with textured surfaces, co-molding, or integral forming. This integration eliminates separate post-processing steps, reducing manufacturing complexity while achieving the desired surface finish quality.
Data Source
AI summary
An assembly comprises a first component having a first structure, and a second component having a second structure corresponding to the first structure. The first and second structures form interlocking profiles. A third component extends over the first and second structures, with the third component maintaining the first and second structures together to form an interlocked section.