Plastic Snap-Fit Connector for Parallel Air Cleaner Assembly
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Solution Overview
Problem
The existing air cleaner systems using metal connectors for parallel connection are costly, difficult to install, and suffer from durability issues due to rigid connections and dimensional tolerance problems.
Innovation Solution
A plastic connector system with a snap-fit design, featuring guide rails, frame legs, and an elastic fastener with position limiters, allowing for easy assembly and self-adjustment to accommodate dimensional deviations, reducing the need for tools and material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal connectors are used to bond air cleaners together, then connection strength is improved, but material cost and processing cost increase significantly
Solution Approach 1:
The patent replaces expensive metal connectors with inexpensive plastic connectors that can be manufactured through injection molding. The plastic connector achieves sufficient connection strength for the application while dramatically reducing both material costs and processing costs compared to metal alternatives.
Solution Approach 2:
The patent changes the material parameter from metal to plastic, which fundamentally alters the cost structure while maintaining adequate mechanical performance. The plastic material allows for complex geometries to be formed through molding, eliminating the need for costly metal fabrication processes.
2Stability of the object's composition
If metal connectors with rigid connection are used, then structural stability is improved, but dimensional tolerance issues cause increased stress and reduced durability
Solution Approach 1:
The patent employs a plastic connector with built-in flexibility that can accommodate dimensional variations and misalignments between air cleaner mounting surfaces. The plastic material's inherent elasticity allows the connector to deform slightly, absorbing tolerance deviations without creating excessive stress concentrations that would compromise durability.
Solution Approach 2:
The connector transitions from a rigid, fixed-geometry metal structure to a dynamic plastic structure that can adapt its shape and position. This dynamic capability allows the connector to self-adjust to dimensional tolerances and maintain reliable connection despite variations in manufacturing accuracy of the air cleaner components.
3Reliability
If metal connectors and screws are used for assembly, then connection reliability is improved, but assembly complexity and installation difficulty increase
Solution Approach 1:
The patent integrates multiple fastening functions into a single plastic connector component. The connector incorporates built-in attachment features such as clips, tabs, or snap-fit mechanisms that combine the functions of alignment, positioning, and securing into one unified part, eliminating the need for separate screws, nuts, and washers required by metal connector assemblies.
Solution Approach 2:
The plastic connector is designed with self-aligning and self-securing features that automatically adjust during installation. The connector may include flexible elements that self-adjust to fit mounting holes, or integrated fastening mechanisms that automatically engage and lock into place without requiring additional fasteners or complex assembly procedures.
4Adaptability or versatility
If plastic connectors with flexibility are used, then adaptability to dimensional deviations is improved, but connection strength may be reduced
Solution Approach 1:
The patent carefully selects and engineers the plastic material properties to achieve an optimal balance between flexibility and strength. By controlling parameters such as material composition, wall thickness, and geometric design, the connector gains sufficient elasticity to accommodate dimensional deviations while maintaining adequate connection strength for the application requirements.
Solution Approach 2:
The connector is designed with segmented or modular features that allow different portions to perform different functions. Rigid sections provide structural strength and mounting attachment, while flexible sections accommodate dimensional variations. This segmentation allows the single plastic component to simultaneously achieve both adaptability and connection strength.
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 plastic connector system provides a cost-effective, tool-free installation method that enhances durability by allowing minor adjustments to accommodate dimensional deviations, reducing installation stress and improving the overall reliability of air cleaners in parallel connection.
Implementation Method 1
The fastener can slide along the guide rails under force
Implementation Method 2
The openings of the fastener are in snap-fit with the guide rails of the connector body
Data Source
AI summary
The present invention provides a plastic connector for bonding two or more air cleaners, comprising a connector body and a fastener. The connector body has guide rails and frame legs; and the fastener has openings and fastener arms. The openings of the fastener are in snap-fit with the guide rails of the connector body, so that the connector body and the fastener form the plastic connector, and the fastener can slide along the guide rails as force applies. The present invention also provides an air cleaner system with air cleaners in parallel connection using the plastic connectors. The plastic connector of the present invention does not require tool for installation, is low in costs, and saves labor and time. Also, such plastic connector reduces installation stress of air cleaners in parallel connection, which facilitates durability of the air cleaners.