Adhesive Node Connector for Large Tube Frame Assembly
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Solution Overview
Problem
Challenges in assembling metal tubes for large frame structures include achieving consistent quality in welds, proper temperature control and timing for brazing, and ensuring proper torque specification for mechanical fastening, which compromise the structural integrity of the finished product.
Innovation Solution
A frame structure design featuring a one-piece node connector with protrusions and recesses for adhesive application, allowing secure and easy connection of tubes, utilizing a recess that extends over the entire circumference for uniform adhesive distribution, and a positioning element for precise alignment, enhancing structural stability and crash resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to join metal tubes, then strong bonds are achieved, but weld consistency and structural integrity are compromised due to difficulty in ensuring strong and consistent welds throughout the assembly
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical connection system consisting of a connection element with external threads that engages with an internal thread in the end portion. This mechanical threading system eliminates the variability inherent in welding processes while maintaining strong structural bonds.
Solution Approach 2:
The invention changes the joining mechanism from thermal bonding (welding) to mechanical threading. The connection element features externally threaded portions that screw into internally threaded portions of the end portions, creating a reliable mechanical fastening system that ensures consistent connection strength throughout the assembly.
2Adaptability or versatility
If brazing is used to join metal tubes, then dissimilar metals can be connected, but proper temperature control and timing are difficult to achieve for even filler metal flow and strong bonding
Solution Approach 1:
The patent replaces the brazing process (thermal system requiring precise temperature control) with a mechanical threading system. The connection element with external threads engages with internal threads in the end portions, eliminating the need for temperature control and filler metal application while achieving strong bonds between dissimilar metals.
3Ease of operation
If mechanical fastening is used to assemble metal tubes, then temporary assemblies and maintenance-friendly designs are achieved, but proper torque specification is difficult to ensure preventing assembly failure
Solution Approach 1:
The invention transitions from simple mechanical fastening (requiring torque control) to a threaded connection system. The connection element features externally threaded portions that screw into internally threaded portions, creating a self-contained fastening mechanism that maintains consistent engagement through the threading geometry itself, reducing dependence on precise torque application.
4Strength
If complex welding or brazing processes are used, then strong connections are achieved, but manufacturing complexity and production time increase
Solution Approach 1:
The patent replaces complex thermal processes (welding and brazing) with a mechanical threading system. The connection element with external threads and the internally threaded end portions create strong connections through simple screw engagement, eliminating the need for expensive welding equipment, temperature control systems, and skilled welders, thereby significantly improving manufacturing efficiency.
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 design ensures strong and consistent connections, providing enhanced structural integrity, crash resistance, and ease of manufacturing, while meeting safety standards for vehicles like tractors.
Implementation Method 1
The protrusion of the node connector comprises a recess for an adhesive. The recess is arranged on the outer circumference of the protrusion and extends essentially over the entire circumference.
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a frame structure comprising a node connector for connecting tubes and a tube designed to be connected to the node connector can provide an easy and secure connection if the node connector is a one-piece part with a main body and at least one protrusion. An inner cross-section of an end portion the tube is at least a wide as the outer cross-section of the protrusion. This enables a proper fit of the tube onto the protrusion of the tube. The end portion of the tube is designed to fit over the protrusion to connect the tube to the connector. The protrusion of the node connector comprises a recess for an adhesive. The recess is arranged on the outer circumference of the protrusion and extends essentially over/via the entire circumference.