Magnetic Building Block Assembly Without Ultrasonic Welding
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Solution Overview
Problem
Existing magnetic building blocks face issues with ultrasonic welding processes that cause noise, pollution, health hazards, and reduced production efficiency due to complex assembly and alignment requirements, leading to quality and stability concerns.
Innovation Solution
A magnetic building block design featuring integrally molded side panels and cover panels with riveting connections, using sockets and insertion columns to stabilize magnetic blocks and eliminate the need for ultrasonic welding, along with separating members to prevent displacement and enhance structural stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If ultrasonic welding technology is used to fix side panels to cover panels, then structural stability is improved, but production efficiency deteriorates due to complex assembly and positioning requirements
Solution Approach 1:
The invention divides the building block into separate components (side panels, upper cover panel, lower cover panel) that are pre-assembled in groups. The side panels are annularly connected end-to-end to form a complete side structure, which is then connected to the cover panels as a unit. This segmentation allows parallel production of different components, improving overall production efficiency while maintaining structural stability through the integrated side panel assembly.
Solution Approach 2:
The invention merges multiple side panels into an annular connection structure where they are fixed together as a unified assembly before being attached to the cover panels. This merging of side panels into a pre-assembled unit simplifies the final assembly process, reducing the number of individual positioning operations required while maintaining the structural stability provided by the welded connections within the side panel assembly.
2Stability of the object's composition
If ultrasonic welding process is used, then structural stability is improved, but harmful factors increase due to noise and harmful gases
Solution Approach 1:
The welding process is segmented into two distinct stages: first, side panels are welded together to form an annular assembly; second, the pre-assembled side panels are connected to the cover panels. This segmentation confines the harmful welding effects to localized areas during manufacturing, while the final product structure maintains stability without requiring continuous welding operations, thereby reducing overall noise and harmful gas generation during production.
Solution Approach 2:
The invention introduces the annularly connected side panels as an intermediary structure between the upper and lower cover panels. This intermediary assembly serves as a stable connecting element that requires welding only at specific junction points rather than continuous welding across all panel connections, thereby reducing the total volume of noise and harmful gases generated during the welding process while maintaining structural integrity.
3Manufacturing precision
If upper and lower cover panels are positioned with side panels one by one, then positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The assembly process is segmented into two main stages: first, multiple side panels are pre-assembled into an annular connection structure with predetermined positioning; second, the pre-assembled side panel unit is connected to the cover panels as a single assembly. This segmentation reduces the number of individual positioning operations from multiple separate panel-to-panel alignments to fewer unit-level connections, simplifying the overall process while maintaining positioning accuracy through the pre-configured annular structure.
Solution Approach 2:
The invention merges multiple side panels into a pre-assembled annular unit that functions as a single assembly component. This merging reduces the complexity of the assembly process by decreasing the number of individual positioning operations required, as the pre-assembled unit maintains internal positioning accuracy while requiring fewer external alignment operations when connected to the cover panels.
4Stability of the object's composition
If traditional welding process is used, then structural stability is improved, but alignment accuracy deteriorates due to deviations in welding process
Solution Approach 1:
The structure is segmented into a pre-assembled annular side panel unit and cover panels. The segmentation allows alignment and positioning to be established during the side panel assembly stage, creating a stable reference framework. Subsequent welding operations are then performed on this pre-aligned structure, reducing cumulative alignment errors while maintaining structural stability through the distributed welding joints in the annular configuration.
Solution Approach 2:
The invention applies preliminary action by pre-assembling the side panels into an annular connection structure with predetermined positioning and alignment before the final welding to the cover panels. This preliminary assembly establishes accurate alignment relationships in advance, allowing subsequent welding operations to be performed on a pre-configured structure, thereby reducing welding-induced alignment deviations while maintaining structural stability.
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 design ensures stable magnetic block placement, improves assembly efficiency, reduces noise and pollution, enhances structural durability, and maintains high production accuracy while maintaining strong magnetic force and adsorption effects.
Implementation Method 1
a plurality of magnetic blocks (8), wherein the magnetic block (8) is configured to be placed in the placement chamber (7)
Data Source
AI summary
A magnetic building block includes a plurality of side panels, an upper cover panel, a lower cover panel, a plurality of magnetic blocks and a plurality of separating members. The plurality of side panels are annularly connected end to end and form a plurality of inner corners, a baffle is arranged on each of two sides of the inner corner, the baffle on each of two sides of the inner corner and the side panel form a placement chamber, and the baffle is provided with a socket. The magnetic block is configured to be placed in the placement chamber, and specifically two magnetic blocks are arranged in each of the placement chambers. The separating member is configured to separate the magnetic blocks within the same placement chamber, and specifically the separating member is configured to separate the two magnetic blocks in the placement chamber.