Toy Block Sawtooth Structure for Fine Angle Adjustment
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Solution Overview
Problem
Conventional toy blocks with sawtooth structures for magnetic coupling face challenges in maintaining three-dimensional structures due to easy collapse and uneven surfaces when building stereoscopic structures, as the coupling angle is not accurately adjustable, leading to aesthetic and structural limitations.
Innovation Solution
The design features a sawtooth structure with an inner and outer sawtooth portion on the inner and outer surfaces, respectively, allowing for fine adjustment of the assembly angle through a rotatable internal sawtooth structure within an external sawtooth structure, with specific ratios of sawtooth and non-sawtooth areas and shapes to enhance rotation resistance and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a cap method is used to couple magnets to toy blocks, then the structure is simple to manufacture, but the three-dimensional structure is unstable and easily collapsed
Solution Approach 1:
The coupling structure is divided into two independent sawtooth components: an external sawtooth structure on the first block and an internal sawtooth structure on the second block. This segmentation allows each component to be manufactured separately with standard processes while achieving enhanced structural stability through their interlocking engagement, resolving the contradiction between manufacturing simplicity and structural stability.
Solution Approach 2:
The internal sawtooth structure is nested within the external sawtooth structure, with the internal structure rotating inside the external structure. This nesting arrangement provides precise angular adjustment capability while maintaining structural integrity, allowing the blocks to form stable three-dimensional configurations without compromising manufacturing ease.
2Ease of manufacture
If blocks are assembled with fixed coupling angles, then the manufacturing process is simple, but the assembled surfaces are uneven and the structure is aesthetically limited
Solution Approach 1:
The internal sawtooth structure is designed to be rotatable within the external sawtooth structure, transforming the static coupling angle into a dynamic, adjustable parameter. This allows precise angular adjustment during assembly to achieve smooth, even surfaces and aesthetically pleasing structures, while the standardized sawtooth geometry maintains manufacturing simplicity.
Solution Approach 2:
The coupling angle is changed from a fixed parameter to an adjustable parameter through the rotation mechanism. The sawtooth geometry provides discrete angular positions, enabling precise control of assembly angles while maintaining simple manufacturing processes for the standardized tooth profiles.
3Manufacturing precision
If a rotatable internal sawtooth structure is used, then the assembly angle can be finely adjusted, but the device complexity increases
Solution Approach 1:
The complex functionality of angular adjustment is achieved through segmentation into two simple, standardized sawtooth components rather than a single complex mechanism. Each component has a straightforward geometry that is easy to manufacture, while their combined interaction provides the desired rotational adjustment capability.
Solution Approach 2:
The sawtooth geometry acts as an intermediary mechanism between the two blocks, providing the rotational adjustment function without requiring complex actuators or control systems. The interlocking teeth serve as a mechanical mediator that translates simple rotational motion into precise angular positioning.
4Stability of the object's composition
If the internal sawtooth structure is tightly fitted, then the rotation resistance is high and stability is improved, but the adjustment precision is reduced
Solution Approach 1:
The fit between internal and external sawtooth structures varies locally along the engagement interface. Certain regions have tighter fits that provide rotation resistance and stability, while other regions allow sufficient clearance for smooth rotation and precise angular adjustment. This local variation in fit quality resolves the contradiction between stability and adjustment precision.
Solution Approach 2:
The clearance or interference fit parameters are optimized to achieve the desired balance between rotation resistance and adjustment precision. By carefully controlling the dimensional parameters of the sawtooth geometry, the design achieves sufficient tightness for stability while maintaining enough freedom for precise angular positioning.
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
This design enables accurate adjustment of assembly angles, resulting in smooth and even assembled surfaces, enhancing the aesthetic appeal and structural stability of the blocks, allowing for precise rotation and assembly of blocks with a desired angle.
Implementation Method 1
a toy block comprising a sawtooth structure and at least one magnet for connecting to a similar block
Data Source
Figure 1
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AI summary
The present invention relates to a sawtooth structure in which an external sawtooth structure and an internal sawtooth structure engage with each other to support a fine joint angle adjustment function, and to a toy block comprising such structure. A sawtooth structure of the present invention comprises an external sawtooth structure and an internal sawtooth structure, wherein the external sawtooth structure has an inner surface with one or more areas on which an inner sawtooth portion of the external sawtooth structure containing at least two or more inner sawteeth of the external sawtooth structure is formed,; and the internal sawtooth structure has an outer surface with one or more areas on which an outer sawtooth portion of the internal sawtooth structure that corresponds to the inner sawtooth portion of the external sawtooth structure and that contains at least two or more outer sawteeth of the internal sawtooth structure is formed. Thus, the coupling angle of the blocks to be coupled by the magnetic force of the magnet can be finely adjusted, and as the coupling angle of the blocks is finely adjusted, the coupled surfaces of the blocks are smooth.