Interlocking Toy Structure Tool-Free Assembly
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Solution Overview
Problem
Conventional toy structures made of wood components often suffer from poor appearance due to poorly formed components, assembly issues, and require tools for assembly/disassembly, leading to frustration and increased costs.
Innovation Solution
An interlocking structure design featuring panels with tabs, grooves, tenons, and mortises that allow for tool-free assembly and disassembly, using a compression fastener to stabilize the structure, enabling easy and efficient assembly and disassembly without the need for tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional wood components are used for assembly, then the structure can be built, but the appearance becomes poor and assembly requires tools
Solution Approach 1:
The structure is divided into multiple panels (front, back, left side, right side, top, bottom) that can be assembled separately and interconnected through standardized joints, enabling tool-free assembly while maintaining structural integrity
Solution Approach 2:
Tabs and grooves are designed to nest within each other, with tabs fitting into grooves to create interlocking connections between panels, eliminating the need for additional fasteners or tools
2Ease of manufacture
If conventional interconnections are used, then assembly is possible, but manufacturing cost increases due to custom machining
Solution Approach 1:
Standardized tabs, grooves, tenons, and mortises are designed to work across all panel types, allowing the same connection mechanisms to be used universally throughout the structure, reducing custom machining requirements
Solution Approach 2:
Tabs, grooves, tenons, and mortises are pre-formed during panel manufacturing with precise dimensions, allowing for accurate interconnections without requiring custom field machining or adjustment
3Ease of operation
If conventional toy structures are assembled, then the structure is formed, but disassembly requires tools and creates frustration
Solution Approach 1:
The connection system allows panels to be dynamically assembled and disassembled by simply pushing tabs into grooves or withdrawing them, enabling easy reconfiguration without tools while maintaining stable connections during play
Solution Approach 2:
The tab-and-groove design allows users to assemble and disassemble panels through simple pushing or pulling motions without requiring external tools, making the structure self-servicing for both assembly and disassembly operations
Data Source
AI summary
An interlocking structure is provided. The interlocking structure includes a floor panel which has a floor tab, a floor groove, and a floor tenon. A side panel includes a first side tab, a second side tab, and a side groove, wherein the side groove is removably coupled to the floor groove. A top panel has a top tab, a top groove, and a top tenon, wherein the top tab is removably coupled to the side groove and the top groove is removably coupled to the first side tab. A back panel has a back tab, a back groove, a first back mortise and a second back mortise. The first back mortise is configured to receive the floor tenon and the second back mortise is configured to receive the top tenon. A rod is removably coupled to at least one of the floor tenon and the top tenon.