Keyway Connector Assembly for Fast, Strong Component Joining
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Solution Overview
Problem
Current methods for connecting components in construction, furniture, and industrial applications are often time-consuming, labor-intensive, and require specialized tools, with inadequate strength and limited material flexibility, especially in flat-pack and ready-to-assemble designs.
Innovation Solution
A connector assembly comprising elongate keyway and key connectors with regularly spaced keyways and keys that provide a longitudinal passage, allowing for secure locking and easy assembly of components or component regions using a friction fit or adhesive, enabling efficient and strong connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional connecting methods (glue, nails, screws, bolts) are used to connect components, then connection strength can be achieved, but the process becomes time-consuming and labor-intensive requiring specialist tools
Solution Approach 1:
The connector is divided into two distinct components: a keyway connector with regularly spaced keyways and a key connector with regularly spaced keys. This segmentation allows for rapid engagement by simply inserting the key connector into the keyway connector, eliminating the need for complex fastening operations while maintaining strong mechanical connection through multiple distributed engagement points
Solution Approach 2:
The connector assembly is designed to be self-aligning and self-securing. The regularly spaced keys automatically engage with the corresponding keyways when the connectors are brought together, creating a locked connection without requiring external tools, specialists, or complex alignment procedures
2Ease of operation
If flat-pack and ready-to-assemble furniture designs are used, then assembly becomes easier and faster, but the connection strength becomes inadequate and relies on point loads
Solution Approach 1:
Instead of relying on a single point connection, the connector distributes the connection force across multiple regularly spaced keys and keyways along the longitudinal axis. This segmentation of the connection interface transforms point loads into distributed line loads, significantly increasing connection strength while maintaining the simplicity of a snap-fit assembly process
Solution Approach 2:
The connector extends the connection interface from a single point or small area into a longitudinal dimension, creating a continuous line of engagement through multiple keys and keyways. This dimensional expansion transforms the connection from a weak point load to a strong distributed load across the length of the connector
3Strength
If tongue in groove arrangements or dovetail joints are used, then strong connections are achieved, but the components must be made of wood (timber or particle board)
Solution Approach 1:
The key and keyway connector design is universally applicable to multiple material types including metals, plastics, composites, and woods. The regularly spaced geometric features provide material-independent engagement, allowing the same connector design to be used across diverse materials and applications such as furniture, construction, and industrial equipment without requiring material-specific design modifications
4Device complexity
If existing panel and modular construction methods are used, then assembly can be simplified, but the same problems of time-consuming assembly and inadequate connection strength persist
Solution Approach 1:
The connectors are pre-configured with regularly spaced keys and keyways during manufacturing, so that during assembly the components simply need to be brought together and the keys automatically engage with the keyways. This preliminary preparation of the connection interface eliminates the need for complex on-site assembly operations, significantly improving productivity while keeping the construction system simple
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
The solution enables faster, more accurate, and cost-effective assembly of components with enhanced strength and flexibility, reducing the need for specialized tools and allowing for permanent, reversible, or reusable joints, while accommodating various materials and complex structures.
Implementation Method 1
allowing for secure locking and easy assembly of components or component regions using a friction fit or adhesive
Implementation Method 2
allowing for secure locking and easy assembly of components or component regions using a friction fit or adhesive
Data Source
AI summary
A method of mechanically connecting two or more components together comprises the steps of: i. mounting an elongate keyway connector (10) comprising regularly spaced keyways (13) to a first component wherein the keyways (13) provide a longitudinal keyway passage (16); ii. mounting at least one elongate key connector (11) comprising regularly spaced keys (14) to a second component; and iii. extending the keys (14) longitudinally within the keyway passage (16) and engaging the keyways (13) with the keys (14) to connect the first and second components together.