Metal Frame Snap-Fit Coupling for Weld-Free Assembly
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Solution Overview
Problem
Existing metal frames require expensive welding or lengthy screw/bolt assembly methods, which are costly and prevent preliminary painting of section bars.
Innovation Solution
The metal frame design incorporates elastically deformable tongues and hooks integrated into the section bars, allowing for simple and cost-effective assembly by inserting and deforming these features during machining, enabling pre-painting and quick coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to connect coupling portions, then connection strength is improved, but manufacturing cost increases and execution time increases
Solution Approach 1:
The patent replaces the welding process (thermal/chemical system) with a mechanical coupling system consisting of tongues, grooves, and hooks. The tongue of one section bar engages with the groove of another, creating a mechanical connection that eliminates the need for welding while maintaining structural integrity through geometric interlocking rather than metallurgical bonding.
Solution Approach 2:
The coupling mechanism is designed to be self-aligning and self-securing. The tongue automatically guides itself into the groove, and the hook engages with the protrusion to lock the connection without requiring additional fasteners or external intervention. This self-service characteristic reduces manufacturing complexity and cost.
2Strength
If welding is used to connect coupling portions, then connection strength is improved, but execution time increases
Solution Approach 1:
The coupling features (tongues, grooves, and hooks) are pre-formed as integral parts of the section bars during manufacturing. This preliminary action eliminates the need for on-site welding operations, allowing sections to be quickly assembled by simply engaging the pre-formed mechanical features, thereby drastically reducing execution time.
3Ease of manufacture
If screws/bolts are used to connect coupling portions, then assembly is simplified, but assembly time increases and additional components are required
Solution Approach 1:
The patent merges the coupling features directly into the section bar structure itself. The tongue, groove, and hook are integral to the section bars, eliminating the need for separate screws, bolts, or other additional fastening components. This merging simplifies the assembly process to a single insertion and engagement motion.
Solution Approach 2:
The mechanical coupling system is designed to be self-securing through the engagement of the hook with the protrusion in the groove. This self-service mechanism eliminates the need for additional fasteners that would require tightening operations, reducing assembly time while maintaining connection integrity.
4Strength
If welding is used to connect coupling portions, then connection strength is improved, but preliminary painting becomes impossible
Solution Approach 1:
The mechanical coupling features are designed to be installed after the section bars have been painted. The tongue, groove, and hook structures allow for post-painting assembly without compromising the paint coating, enabling preliminary painting operations to be performed on all exposed surfaces before final assembly, thereby improving aesthetic appearance and corrosion protection.
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 design reduces assembly time and costs, allowing for painted section bars to be easily connected without additional components, resulting in a more efficient and inexpensive metal frame construction process.
Implementation Method 1
elastically deformable tongues
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A metal frame is provided with at least one first section bar (4; 25) having an end portion, which defines a first coupling portion (7; 29), and is delimited by two first side walls (8; 30) which are substantially parallel to one another, and with at least one second section bar (2; 23) having a second coupling portion (15; 16; 27) delimited by a second side wall (14; 28); each first side wall (8; 30) being provided with at least one elastically deformable tongue (9; 31), which is laterally delimited by at least one slit (10, 11; 32), and has a hooking tooth (12; 33) designed to engage the second side wall (14; 28) following the coupling of the first coupling portion (7; 29) to the second coupling portion (15; 16; 27).