Modular Panel Kit With Integral Slots For Fast Assembly
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Solution Overview
Problem
Existing static structures formed from single self-supporting panels require additional connecting means for assembly, increasing parts and manufacturing costs, and complicating shipping, storage, and reconfiguration.
Innovation Solution
A kit comprising planar panels with integral connectors and slots that allow for interlocking to form three-dimensional shapes without additional fastening means, enabling the creation of various geometric structures such as tetrahedrons and pentagons, which can be easily assembled and disassembled for reconfiguration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If additional separate connecting means are used to assemble panels, then the structural stability and strength are improved, but the number of parts increases, manufacturing cost increases, and assembly complexity increases
Solution Approach 1:
The connector is integrally formed with the panel, merging the panel and connector into a single component. This eliminates separate connecting means while maintaining structural strength, directly reducing parts count and assembly complexity
Solution Approach 2:
The panel includes self-contained connecting features (integrally formed connectors with slots) that enable assembly without external fastening means. The structure assembles itself through the interlocking slots and connectors that are part of the panel design
2Stability of the object's composition
If additional separate connecting means are used to assemble panels, then the structural stability is improved, but the manufacturing cost increases
Solution Approach 1:
By integrating the connector with the panel as a single component, the manufacturing process is simplified. Instead of producing separate connectors and assembling them, the entire assembly is manufactured as one piece, reducing manufacturing steps and cost while maintaining structural stability
Solution Approach 2:
The panel's self-contained design with integrally formed connectors eliminates the need for separate connecting components, reducing parts inventory, assembly operations, and associated manufacturing costs while preserving structural integrity
3Strength
If panels are designed as complete three-dimensional structures, then the structural integrity is improved, but the flat pack capability and ease of shipping are worsened
Solution Approach 1:
The three-dimensional structure is segmented into flat panels with integrally formed connectors. These panels can be nested or stacked in a compact flat pack configuration for shipping, then assembled into the complete three-dimensional structure at the destination, reducing shipping volume while maintaining structural integrity
Solution Approach 2:
The flat panels with connectors can be nested within each other or stacked in a compact arrangement for shipping and storage. The integrally formed connectors remain attached to the panels, allowing easy assembly into the complete three-dimensional structure without requiring separate connecting components
4Ease of operation
If separate connecting means are used, then the ease of disassembly and reassembly is improved, but the number of required parts increases
Solution Approach 1:
The panel includes self-contained connectors that enable easy disassembly and reassembly without requiring separate fastening components. The integrally formed slots and connectors allow panels to be easily separated and reconnected, maintaining ease of operation while reducing the total number of parts
Data Source
AI summary
Panels can join to form a structural module via slotting, abutment, and rotational symmetry. The slots allow for assembly without additional fastening. Modules can range in shape and size, while conforming to the interlocking configuration between the panels. Panels can be joined to form various structures with similar connective features. The panel's combinability via the slots makes possible many structural forms and re-configurable applications.