Rotary Connecting Structure Reducing Assembly Time and Gap
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Solution Overview
Problem
Existing rotary coupling structures require hand-assembling of two members and often have significant gaps between components, which is time-consuming and inefficient, and the mold structure for forming these connections can be complex.
Innovation Solution
A rotary coupling structure comprising a primary and secondary molded product, both injection-molded from resin, where the primary product includes a shaft that rotates after being moved into contact with a bearing portion on the secondary product, reducing the need for hand-assembling and minimizing the gap between components to less than 0.5 mm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hand-assembling is used to engage the hook with the bar, then the engagement can be achieved, but it requires time and effort
Solution Approach 1:
The patent merges the hook member and bar into a single injection-molded component, eliminating the need for hand-assembling two separate members. The integrated design allows the coupling structure to be formed in one manufacturing process, thereby eliminating assembly time and effort while maintaining the functional engagement between the hook and bar.
Solution Approach 2:
The injection-molded coupling structure serves multiple functions: it provides the hook engagement, structural support, and rotational coupling capability all in one component. This multi-functionality eliminates the need for separate assembly operations while achieving the same mechanical results.
2Loss of time
If the neck is fitted in the through hole to eliminate hand-assembling, then assembly time is reduced, but the gap between the neck and through hole increases
Solution Approach 1:
By merging the hook member and bar into a single injection-molded component, the patent eliminates the gap control issue entirely. The integrated design ensures precise positioning and minimal gap between the coupling surfaces without requiring manual assembly or complex mold structures.
Solution Approach 2:
The injection molding process allows for precise control of dimensional parameters, including the gap between coupling surfaces. By optimizing the molding parameters and design, the patent achieves a gap of less than 0.5 mm while maintaining the automated manufacturing advantage.
3Ease of manufacture
If a mold structure is used to form the fitted state, then hand-assembling is eliminated, but the mold structure becomes complicated
Solution Approach 1:
The patent combines multiple functions into a single injection-molded component, which simplifies the overall manufacturing process. While the mold structure for injection molding is inherently complex, the integrated design eliminates the need for additional assembly molds or complex multi-step molding processes, thereby reducing overall manufacturing complexity.
Solution Approach 2:
The coupling structure is designed as a single integrated component rather than multiple parts requiring assembly. This segmentation approach, where the entire coupling mechanism is formed in one molding operation, reduces the complexity of mold structures needed for multi-step assembly processes.
4Manufacturing precision
If the shaft is contact-coupled to the bearing portion, then the gap is reduced, but the shaft needs to be moved into rotation state
Solution Approach 1:
The shaft is pre-configured in the injection-molded component to be in contact-coupled position with the bearing portion. This preliminary positioning ensures minimal gap from the start, and the rotational movement is designed to be a simple single action rather than a complex assembly process.
Solution Approach 2:
By integrating the shaft and bearing portion in a single component, the patent eliminates the need for complex alignment and gap control that would be required if these were separate parts. The contact-coupled state is achieved automatically through the integrated design, requiring only a simple rotational movement to activate.
Data Source
AI summary
A halter snap includes a hook member serving as a primary molded product and a holder member serving as a secondary molded product, the hook member and the holder member being injection-molded from resin and rotatably coupled to each other. The primary molded product includes a shaft formed irreducible in diameter. The secondary molded product includes a bearing portion coupled to the shaft and formed unincreasable in diameter. The shaft is configured to rotate after being moved in an X-axis direction from a state where the shaft is contact-coupled to the bearing portion. The hook member and the holder member include POM.