Three-Sided Channel Sign Coupler Friction Fit
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing two-piece stake systems for yard signs require hole punching and screwing, which increases material and labor costs, as well as shipping and packaging expenses, and lacks a more efficient method for connecting sign pieces.
Innovation Solution
A three-sided U-shaped coupler made of lightweight nylon, comprising two U-shaped elements with cross-braces and vertical ribs, that securely holds together upper and lower U-shaped stakes without the need for screws, providing a frictional fit and a stop mechanism to maintain assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two stakes are connected by punching holes and affixing with screws, then the stakes are securely held together, but material and labor costs increase
Solution Approach 1:
The patent replaces the mechanical fastening system (holes and screws) with a friction-based mechanical interference fit system. The coupler uses vertical ribs that create frictional contact with the stakes, eliminating the need for holes and screws while maintaining connection strength. This substitution reduces both material costs (no screws needed) and labor costs (simpler assembly).
Solution Approach 2:
The coupler design allows the stakes to self-align and self-secure within the coupler through the frictional fit mechanism. The vertical ribs automatically grip the stakes when inserted, eliminating the need for additional fastening operations. The system serves itself by using the insertion force to create the secure connection without requiring separate fastening steps.
2Reliability
If two stakes are connected by punching holes and affixing with screws, then the stakes are securely held together, but shipping and packaging expenses increase
Solution Approach 1:
By replacing screws with a friction-based interference fit, the patent eliminates the need for separate fastening components and their associated packaging. The coupler and stakes can be packaged more simply without requiring protective packaging for screws or complex assembly instructions, reducing packaging material and shipping complexity.
3Strength
If a single piece stake is used, then the stake is structurally complete, but shipping and packaging costs increase
Solution Approach 1:
The patent divides the stake system into modular segments (stakes and a separate coupler) that can be shipped separately and assembled at the destination. This segmentation allows for more efficient packaging and shipping of individual components, reducing overall shipping costs compared to shipping complete assembled units or requiring protective packaging for single-piece stakes.
Solution Approach 2:
The coupler is designed to receive and hold multiple stakes within its structure. The nested configuration allows stakes to be stored within the coupler when not in use, creating a compact assembly for shipping that reduces the overall volume and packaging requirements compared to shipping separate components or complete assembled structures.
4Reliability
If a coupler with vertical ribs is used, then the stakes are held tightly by friction, but the coupler design becomes more complex
Solution Approach 1:
The coupler features vertical ribs only at specific locations where contact with the stakes is needed, rather than a uniformly complex structure. This local addition of ribs provides the necessary frictional holding strength at critical contact points while keeping the rest of the coupler structure simple and easy to manufacture.
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 solution simplifies the assembly process, reduces material and labor costs, and lowers shipping and packaging expenses by eliminating the need for hole punching and screwing, while maintaining the structural integrity of the sign posts.
Implementation Method 1
The vertical ribs on the inside of the larger U-shaped element and on the outside of the smaller U-shaped element act to hold the U-shaped sign post/stake frictionally tightly in place.
Data Source
AI summary
A three-sided channel coupler for connecting the upper and lower portions of a U-shaped sign post, the coupler comprising two U-shaped elements, an outer three-sided, U-shaped element and an inner, three-sided U-shaped element, the three sides of each element comprising a transverse face and two lateral legs, the inner element being smaller than the outer element, a plurality of cross-braces attached to the two lateral legs of each element to hold the two elements together and a plurality of vertical ribs on the inner surface of the outer element and on the outer surface of the inner element.