Broach-Formed Integral Chip Retainer for Permanent Connection Joints
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Solution Overview
Problem
Existing permanent connection joints for structures, such as bore and shaft connections, often require separate retainer rings and grooves, which can be cumbersome and unnecessary, and there is a need for a method that eliminates the need for these additional components while ensuring a secure, permanent lock.
Innovation Solution
A method where a post with a knurl and recess is inserted into a socket, with the knurl projections acting as broaching implements to form broach chips on the opposing surface, which are captured in the recess, creating a self-formed integral chip retainer that permanently locks the post in the socket, eliminating the need for a separate retainer ring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate retainer rings and grooves are used in permanent connection joints, then the connection security is improved, but the device complexity increases
Solution Approach 1:
The patent merges the retainer function with the post itself by forming an integral chip retainer directly on the post surface through broaching. This eliminates the need for separate retainer rings and grooves, reducing component count while maintaining the locking function. The chip retainer is formed as a single integrated feature on the post that engages with the socket to prevent disassembly.
2Reliability
If separate retainer rings are used, then the permanent lock is ensured, but the ease of manufacture deteriorates
Solution Approach 1:
The chip retainer is pre-formed on the post surface through broaching before the post is inserted into the socket. This preliminary action creates the locking feature in advance, so that during assembly, the retainer simply engages with the socket to form the permanent connection. The broaching process prepares the retainer geometry beforehand, simplifying the final assembly operation.
3Manufacturing precision
If knurl projections are used as broaching implements, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
The knurl projections on the post surface serve multiple functions: they act as broaching implements to form the chip retainer geometry, and they also provide surface engagement features for the connection. This multi-functionality allows a single structural feature to perform both the broaching operation and contribute to the connection integrity, reducing the need for additional specialized components.
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 provides a secure, permanent connection without the need for additional retainer rings or grooves, enhancing the structural integrity and simplifying the connection process by forming a self-contained locking mechanism during assembly.
Implementation Method 1
the one or more knurl projections act as broaching implements that broach the surface of the opposing post or socket and form one or more broach chips on the surface
Data Source
AI summary
A method for forming a permanent connection joint to interconnect structures. The method may include inserting a post on a first structure into a socket on a second structure, with one of the post or the socket being configured to form an integral chip retainer on the other of the post or the socket during the inserting that permanently locks the post in the socket. In another aspect, a permanent connection joint is provided. The connection joint may include a post disposed in a socket, a chip retainer integrally formed on one of the post or the socket, and a recess formed on the other of the post or the socket, the chip retainer being lockingly engaged in the recess. In example embodiments, the integral chip retainer is formed by broaching as the post is installed in the socket during connection formation.