Split-Tongue Locking Connector Step Angle Optimization
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Solution Overview
Problem
The existing methods for fabricating sidewall steps in panel grooves for spring-loaded split-tongue locking connector systems are limited by excessive tool heating and cutting chip removal difficulties, making it challenging to achieve economical commercial production rates using rotary router cutters or linear broach cutters.
Innovation Solution
Reducing the angle of the step edge from 75° to 65° allows for the use of a rotary circular saw, enabling high-speed production while maintaining the structural integrity and holding strength of the connector system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rotary router cutters or linear broach cutters are used to cut steps at 75° to 85° angles, then the holding strength and structural integrity are maintained, but excessive tool heating and cutting chip removal difficulties occur, preventing economical commercial production rates
Solution Approach 1:
The patent changes the critical parameter of step angle from the conventional 75° to 85° range to a new range of 15° to 45°. This parameter change enables the use of rotary circular saws instead of rotary router cutters or linear broach cutters, allowing high-speed production at economical commercial rates while maintaining adequate holding strength through the optimized angle range
2Productivity
If cutting speed is increased to achieve economical commercial production rates, then productivity improves, but tool heating becomes excessive and cutting chip removal becomes difficult
Solution Approach 1:
By changing the step angle parameter to 15° to 45°, the patent enables the use of rotary circular saws that can operate at high speeds without excessive tool heating. The new angle geometry allows for more efficient chip evacuation and reduced friction, enabling economical commercial production rates to be achieved
3Productivity
If rotary circular saw is used for high-speed production, then productivity and cost-effectiveness improve, but the step angle must be reduced from 75° to 65° to accommodate the tool's cutting capabilities
Solution Approach 1:
The patent deliberately changes the step angle parameter from the conventional 75° to 85° to a new range of 15° to 45° specifically to enable the use of rotary circular saws. This parameter change balances the need for high-speed production with adequate holding strength, as the new angle range is optimized for rotary circular saw cutting while maintaining functional performance
Data Source
AI summary
A method of mechanically joining wood panels side edge to side edge by providing a panel with a groove between a top and bottom surfaces of the panel having two holding ramps with an angle of between 25 degrees and 60 degrees relative to the groove insertion axis which is parallel to the top surface; providing a connector adapted to mate with the groove of the panel having two right-side sub-tongues extending from right side and two left-side sub-tongues extending from the left side of a rectangular base support, and outward extending distal catches on the sub-tongues in a direction substantially normal to the groove insertion axis; and inserting the sub-tongues with distal catches into the groove along the groove insertion axis allowing the distal catches on the two right-side or two left-side sub-tongues to touch the two holding ramps causing the sub-tongues to flex.