Modular Load Compartment Door With Shape-Coupled Module Assembly
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Solution Overview
Problem
Existing solutions for load compartment doors in industrial vehicles are either custom-made and expensive or complex and costly due to their one-piece or multi-module designs with intricate fixing systems, making them difficult to manufacture and assemble.
Innovation Solution
A modular door system comprising hollow modules with counter-shaped head profiles and elastic cantilevered flaps for shape coupling, along with crosspieces and mechanical coupling means, allowing for adjustable width and simplified assembly, reducing production costs and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If leaves or doors are made in one piece according to the height and width of the access, then the structural integrity is maintained, but the manufacturing cost increases due to custom-made production
Solution Approach 1:
The leaf or door is divided into multiple modules that can be assembled together to form the complete structure. Each module can be manufactured independently using standardized processes, reducing custom-made production costs while maintaining the overall structural integrity through the connection system between modules
2Ease of manufacture
If leaves or doors are manufactured in several adjacent modules, then the manufacturing cost decreases, but the device complexity increases due to complex interlocking fixing systems
Solution Approach 1:
The structure is segmented into modules with simplified connection interfaces. The fixing system uses basic mechanical elements like pins or clips that can be easily manufactured and assembled, avoiding complex interlocking mechanisms while still enabling modular construction
Solution Approach 2:
The modules are designed with universal connection features that can be used across different module types and configurations. The fixing system serves multiple functions including mechanical connection, alignment, and potential disassembly/reassembly capabilities, reducing the need for specialized complex fixtures
3Adaptability or versatility
If leaves or doors are manufactured in several adjacent modules, then the adaptability increases for different access sizes, but the ease of assembly decreases due to complex fixing systems
Solution Approach 1:
The modular design allows the leaf or door to be configured in different arrangements to fit various access sizes. The simplified connection system enables end users to easily assemble and disassemble the modules without requiring specialized tools or complex procedures, maintaining both adaptability and ease of assembly
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 modular design enables cost-effective production and assembly, simplifies logistics, and allows for easy customization and assembly by the final user, while maintaining structural integrity and versatility for various applications.
Implementation Method 1
said cantilevered flaps 20 are elastic along an axial direction Z-Z, perpendicular to the main longitudinal direction X-X and to the transverse direction Y-Y, so as to flex to accommodate said male portion 28
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A modular leaf or door (4) comprising a plurality of modules (8) extending along a main longitudinal direction (X-X), the modules (8) being provided with head profiles (16) at least partially counter-shaped to each other, wherein at least one head profile (16") of a first module (8') comprises a pair of cantilevered flaps (20), mutually facing each other with respect to a transverse direction (Y-Y), and wherein at least one head profile (16") of a second module (8"), comprises a male portion (28) adapted to engage in said attachment volume (24). At least one of said cantilevered flaps (20) comprises a first fixing portion (32) having a plurality of ridges (36) and grooves (40) and facing the attachment volume (24), and wherein said male portion (28) comprises a second fixing portion (44), facing the first fixing portion (32) and adapted to obtain a shape coupling with the latter.