Snap-In Modular Assembly Using Protrusion and Recess Interlocking
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Solution Overview
Problem
Existing modular structures require tools for assembly and disassembly, leading to inefficiencies and potential damage to the components due to the need for screwing and unscrewing, which also limits reusability.
Innovation Solution
A modular structure with snap-in assembly that uses recesses and protrusions to allow for tool-free joining and disjoining of modular parts, utilizing a wedge-shaped protrusion that fits into a complementary perforation to secure the parts together.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If modular structures are joined by screwing, then strong connection is achieved, but tool requirement and assembly time increase
Solution Approach 1:
The connection system is segmented into separate functional elements: a protrusion element that provides the connecting feature and a recess element that receives it. This segmentation allows the protrusion to be integrated into one modular component while the recess is integrated into another, enabling tool-free snap-in assembly while maintaining connection strength through the interlocking geometry of the segmented parts.
Solution Approach 2:
The snap-in connection system is designed to be self-servicing during assembly and disassembly. The protrusion and recess are dimensioned and shaped such that the protrusion automatically engages with the recess through elastic deformation and mechanical interlocking without requiring external tools or fastening operations, thereby achieving ease of operation while maintaining adequate connection strength.
2Reliability
If screws and nuts are used for joining, then secure connection is achieved, but assembly time and complexity increase
Solution Approach 1:
The protrusion and recess are pre-configured with specific geometric dimensions and elastic properties during manufacturing. The protrusion is designed with sufficient elasticity to deform during insertion and lock into the recess, while the recess is pre-shaped to receive and retain the protrusion. This preliminary configuration ensures reliable connection upon simple snap-in engagement, eliminating the time-consuming process of selecting, inserting, and tightening screws and nuts.
3Adaptability or versatility
If repeated screwing and unscrewing is performed, then modular parts can be reassembled, but damage to components occurs
Solution Approach 1:
The protrusion element is designed as a replaceable component with sufficient elasticity to withstand repeated engagement and disengagement cycles. When the protrusion becomes worn or damaged after multiple reuse cycles, it can be easily replaced by removing the affected modular component and installing a new protrusion, thereby maintaining the reusability of the overall modular system without compromising the integrity of the main structural components.
4Ease of operation
If simple pressure-based assembly elements are used, then quick assembly is achieved, but stability decreases
Solution Approach 1:
The protrusion and recess are designed with asymmetric geometries that provide directional engagement. The protrusion has a specific shape with varying cross-sectional dimensions along its length, while the recess is complementarily shaped to receive it. This asymmetry ensures that the protrusion can be inserted in only one orientation and provides multi-point contact upon engagement, creating a stable mechanical interlock that resists separation forces while maintaining quick snap-in assembly.
Solution Approach 2:
The protrusion and recess incorporate curved surfaces and rounded edges in their geometric design. The protrusion features a curved engagement surface that facilitates smooth insertion into the recess, while the recess has corresponding curved receiving surfaces that guide and secure the protrusion. This use of curvature enhances the stability of the connection by distributing contact forces across curved surfaces, preventing stress concentration, and maintaining structural integrity under load while enabling easy snap-in assembly.
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
Enables easy and efficient assembly and disassembly of modular structures without the need for tools, reducing the risk of damage and enhancing reusability, while providing a stable and secure connection.
Implementation Method 1
the said protrusion, which is dimensioned to tightly fit in a complementary perforation provided to that effect in an area of the modular part to be joined, close to its edge and that, in turn, is tightly fitting between the walls that define the recess, so that, when inserting the said area of the modular part to be joined in the recess of the assembling element and pressing to overcome the thickness that the protrusion determines
Data Source
AI summary
A modular structure with snap-in assembly includes: one or more modular parts (2) to be joined, that possess, at least, one perforation (20) or one protrusion (13) located close to one of its edges (21); and one or more assembling elements (1) provided with, at least, one recess (10) with, at least, one protrusion (13) or an internal perforation (20) in which the perforation (20) or the protrusion (13) of the modular part or parts (2) complementarily fit when inserting it by the edge (21) in the said recess (10), so that the complementary fitting of the protrusion (13) in the perforation (20) allows to join the part or parts (2) by snap-in to the assembling element or elements (1) without using tools.