Toy Building Element Hybrid Friction Snap-Lock Coupling

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Solution Overview

Problem

Existing toy building elements face issues with friction coupling leading to loose connections over time due to cold deformation, high manufacturing costs, and incompatibility with snap-lock mechanisms, which are expensive and difficult to produce using high-quality plastics and precise molding tools.

Innovation Solution

A toy building element that combines friction coupling and snap-lock coupling mechanisms, where the snap-lock mechanism is designed with locking protrusions that are elastically relieved during interconnection, allowing for increased stability and compatibility with existing elements, while being injection-molded using simpler tools and materials, reducing manufacturing costs and environmental impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If friction coupling is used with elastic resilient walls, then coupling force is achieved, but cold deformation occurs over time causing coupling force to become loose

Engineering Contradiction:

Improvecoupling forceVSAvoidlong-term stability of coupling force

Core Design Contradiction:

ForceVSDuration of action of moving object

Solution Approach 1:

The coupling system is divided into two distinct mechanisms: friction coupling areas for initial connection and snap-lock coupling areas for long-term stable connection. This segmentation allows each mechanism to perform its specific function optimally without the drawbacks of using either alone.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent combines friction coupling and snap-lock coupling into a single hybrid system. The friction coupling provides initial connection and positioning, while the snap-lock coupling provides long-term stable connection, merging the advantages of both mechanisms.

Inventive Principle:

Principle #5Merging (Combining)

2Stability of the object's composition

If snap-lock coupling is used with rigid plastics, then coupling stability is improved, but manufacturing complexity increases and injection molding becomes difficult

Engineering Contradiction:

Improvecoupling stabilityVSAvoidinjection molding feasibility

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The walls are designed with different local properties: regions with sufficient thickness for rigid snap-lock coupling areas and thinner regions for friction coupling areas. This local differentiation allows the structure to achieve both stability and manufacturability.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The snap-lock protrusions are designed to be elastically resilient, allowing them to deform during injection molding and interconnection, then return to their original shape to provide stable coupling. This dynamic behavior enables both easy manufacturing and stable connection.

Inventive Principle:

Principle #15Dynamics

3Strength

If sufficient wall thickness is used to achieve coupling force, then coupling strength is improved, but manufacturing cost increases

Engineering Contradiction:

Improvecoupling strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The wall thickness is optimized locally: thicker walls are provided only where snap-lock coupling is required to achieve sufficient coupling strength, while other areas maintain thinner walls to reduce material consumption and manufacturing cost.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Instead of providing uniform thick walls throughout, the patent provides sufficient wall thickness only where necessary for snap-lock coupling functionality, using partial action to achieve the required strength while minimizing material usage.

Inventive Principle:

Principle #16Partial or excessive action

4Manufacturing precision

If high accuracy molding tools are used to achieve well-defined coupling force, then coupling precision is improved, but manufacturing cost increases

Engineering Contradiction:

Improvecoupling force precisionVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The snap-lock protrusions are designed with elastic resilience that compensates for molding variations. This inherent cushioning effect reduces the sensitivity to molding precision requirements, allowing acceptable coupling force with less precise tools.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The patent changes the material parameter by using elastically resilient plastics for snap-lock protrusions, which allows the system to tolerate greater variations in molding dimensions while maintaining functional coupling force.

Inventive Principle:

Principle #35Parameter changes

5Stability of the object's composition

If round-going protruding bead is used for snap-lock coupling, then coupling stability is improved, but element cannot be injection-molded due to tool withdrawal prevention

Engineering Contradiction:

Improvesnap-lock stabilityVSAvoidinjection molding feasibility

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

Instead of using a protruding bead that prevents tool withdrawal, the patent uses recesses with snap-lock protrusions that allow the molding tool to be withdrawn easily while still providing stable snap-lock coupling functionality.

Inventive Principle:

Principle #13The other way round (Inversion)

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

The combined friction and snap-lock coupling system provides a long-term stable coupling force, reduces manufacturing costs, and ensures compatibility with existing elements, while minimizing material usage and cold flow issues, making it suitable for both traditional and 3D manufacturing processes.

Implementation Method 1

the locking protrusions are substantially elastically relieved when the element is interconnected with said corresponding building element

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

said coupling areas comprising coupling areas that are configured for friction coupling

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS10682581B2Toy building element

Publication Date: 2020.06.16 OCTAVIO APS

AI summary

A toy building element comprising primary coupling means that extend from a top wall and comprise a cavity that contains secondary coupling means that are configured for being able to cooperate frictionally with the primary coupling means on a neighbouring element in a number of friction areas. According to the invention there are also primary locking means that are situated at the end of notches in the primary coupling means, wherein the locking means are configured for snap-lockingly engaging with secondary locking means in the cavity of a neighbouring element in same locking areas that are situated outside said friction areas, in which the secondary locking means are elastically resilient in directions in parallel with the top wall of the building element and are substantially elastically relieved in an interconnected position. The coexistence of friction- and snap-locking means entails is that the element yields a far higher coupling force than the known elements, that cold flow is almost eliminated, and that the element is compatible with the known elements.