Rotational Foam Connector System for Secure Surfboard Assembly
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Solution Overview
Problem
Solid foam products, such as surfboards and paddleboards, are difficult to connect reliably due to their weak structure, which can lead to damage and poor connectivity over time, especially under stress, and existing connectors are often cumbersome and unreliable.
Innovation Solution
A connector system comprising hollow coupling members embedded in adjacent foam sections, connected by a cylindrical connector with internal projections and channels that allow for secure locking and unlocking through rotational alignment, utilizing an actuator rod for easy assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If typical connectors are used to connect foam sections, then the board can be assembled, but the connection is not reliable and does not firmly hold sections together under stress
Solution Approach 1:
The connector member is designed to rotate from an inserted position to a locked position, transforming a static connection into a dynamic locking mechanism. This rotation enables the connector to engage with the coupling members and firmly hold sections together under stress, resolving the unreliability of typical connectors
Solution Approach 2:
The connector system is divided into separate components: a connector member and multiple coupling members embedded in foam sections. This segmentation allows each component to be optimized independently - the connector member for reliable locking through rotation, and the coupling members for secure embedding in foam, thereby improving overall connection reliability and strength
2Strength
If connectors are designed to be secure and reliable, then connection strength improves, but the connectors become awkward to use
Solution Approach 1:
The rotation mechanism transforms a complex multi-step assembly process into a simple single-motion operation. The connector member rotates from inserted to locked position in one continuous motion, making assembly intuitive and easy while maintaining strong connections
Solution Approach 2:
The connector member's rotation automatically engages it with the coupling members, creating the locked position without requiring additional fastening steps or complex manipulation. The design itself performs the locking function through the simple rotational motion, improving ease of operation while ensuring secure connection
3Length of moving object
If foam sections are made into smaller sections for easier transport, then transportability improves, but the connection mechanisms become more critical and complex
Solution Approach 1:
The connector system is segmented into a connector member and multiple coupling members, allowing the connection function to be distributed across multiple simple components rather than requiring a single complex mechanism. This keeps the overall system simple despite the need for reliable connections between multiple sections
Solution Approach 2:
The rotational locking mechanism provides a simple dynamic action that creates a secure connection without complex structures. The rotation from inserted to locked position is a single intuitive motion that simplifies the connection process despite the critical nature of connecting multiple foam sections
Data Source
AI summary
Connector systems for, for example, polymeric solid foam products and products using such systems are disclosed. The connector systems may comprise a pair of hollow coupling members embedded in adjacent foam bodies, such as sections of a surfboard or paddleboard. When axially aligned, the coupling members may be connected together by a connector member that extends into each coupling member. The coupling members have internal projections. The connector member has bent connector channels along which the projections can travel when the connector member is rotated about its axis and in so doing the foam bodies may be connected together or disconnected.