Modular Panel Assembly with Tool-Free Interlocking Frame Members

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Solution Overview

Problem

Existing panel assembly methods are complex, time-consuming, and require multiple tools, making them difficult to assemble, disassemble, and reconfigure, especially for different configurations and user sizes, and they often lead to alignment and breakage issues.

Innovation Solution

A modular frame assembly system that allows for tool-free assembly, disassembly, and reconfiguration using flange portions and receiving members, enabling secure interlocking without screws or bolts, and can be adapted for various configurations and user ages.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional magnetic frames, brackets and fastening members are used to join panels, then the panels can be securely connected to form barriers and walls, but the assembly process becomes complicated, time-consuming, and requires multiple tools

Engineering Contradiction:

Improvesecure connectionVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent removes traditional fastening members (screws, bolts, magnetic frames, brackets) from the panel joining system. Instead, panels are designed with integrated receiving channels and protruding edges that interlock directly, eliminating the need for separate connecting devices while maintaining secure connections

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent combines the functions of panel connection and structural support into a single integrated system. The receiving channels and protruding edges are built into the panel structures themselves, merging what were previously separate components (fasteners and panels) into a unified interlocking system

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If traditional fastening members and brackets are used to connect panels, then panels can be joined together, but disassembly and reconfiguration become difficult and time-consuming

Engineering Contradiction:

Improvepanel connectionVSAvoiddisassembly ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent divides the panel system into modular units with standardized receiving channels and protruding edges. Each panel can be independently connected and disconnected from others in the sequence, allowing for easy disassembly and reconfiguration without affecting the entire structure

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of using fastening members that require tools to remove (screws, bolts), the patent inverts the approach by using protruding edges that push into receiving channels. The connection is established by insertion and maintained by friction and geometry, allowing simple pulling or lifting motions for disassembly

Inventive Principle:

Principle #13The other way round (Inversion)

3Reliability

If traditional panel joining methods are used, then panels can be connected, but alignment problems occur leading to inadvertent disengagement and breakage

Engineering Contradiction:

Improvepanel connectionVSAvoidalignment precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent uses asymmetric receiving channels and protruding edges where the geometry is designed to guide alignment during insertion. The channel shape and edge profile work together to automatically align panels correctly, preventing misalignment and inadvertent disengagement

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The receiving channel acts as an intermediary element between two panels. It provides a guided path for the protruding edge, ensuring proper alignment and distribution of forces during connection, thereby preventing misalignment and breakage

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If traditional fastening systems are used to assemble panels, then structural integrity can be maintained, but the system cannot be easily adapted for different configurations and user sizes

Engineering Contradiction:

Improvestructural integrityVSAvoidconfiguration adaptability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent designs panels with universal receiving channels and protruding edges that can connect to any other panel in the system regardless of position or orientation. This standardized interface allows the same components to be used in multiple configurations and arrangements while maintaining structural integrity

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent creates a dynamic panel system where the number, arrangement, and configuration of panels can be easily changed by connecting and disconnecting modules. The interlocking mechanism remains the same, but the overall structure can be reconfigured for different uses, sizes, and applications

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS11653756B2Modular panel assembly

Publication Date: 2023.05.23 FIVO DESIGN INC

AI summary

Discussed herein are modular frame assemblies, and methods of forming modular frame assemblies. A modular frame assembly includes a first and second lateral frame member each comprising an elongated transverse portion including a flange portion, the transverse portion including an upper edge, a first and second side frame member each comprising a first end, a second end, and a cross panel extending therebetween, the first and second end including one or more receiving members to receive the flange portions of the first and second lateral frame members, and a top planar member having an upper surface and lower surface, the lower surface including one or a plurality of chambers to receive the upper edge of the transverse portion of the first and second lateral frame members.