Captive Disc Reshaping for Uniform Connector Head Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connection units face challenges in reliably and efficiently securing a disc on a connector shank, particularly under unfavorable dimensional conditions, which can lead to incomplete seating of the screw head and compromised sealing performance.
Innovation Solution
The method involves reshaping an annular disc body with a preliminary non-circular outer contour and inner contour, using radial deformation forces to create a final inner contour that securely fixes the disc on the connector shank, ensuring a circular outer contour for uniform contact with the connector head, thereby ensuring captive fixation and reliable sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the disc body is pressed together from two diametrically opposite sides to create an oval or elliptical ring contour, then the disc can be secured on the connector shank, but the connector head no longer lies completely on the disc body under unfavorable dimensional conditions
Solution Approach 1:
The patent applies asymmetry by providing the disc body with a non-circular preliminary outer contour (such as polygonal with rounded corners) before plastic reshaping. This non-circular contour is strategically designed so that when radially directed deformation forces are applied, the disc body deforms into a circular final outer contour that ensures complete contact with the connector head, while simultaneously creating the oval or elliptical inner contour for captive securing on the connector shank.
Solution Approach 2:
The patent implements preliminary action by pre-shaping the disc body with a non-circular preliminary outer contour and preliminary inner contour before mounting on the connector shank. This preliminary configuration allows the disc to be easily placed on the shank, and subsequent radially directed deformation forces transform it into the final configuration with circular outer contour and oval/elliptical inner contour, ensuring both complete connector head contact and reliable captive securing.
2Reliability
If the inner contour is reshaped by plastic deformation to effect captive fixation, then the disc is securely held on the connector shank, but the outer contour may become non-circular leading to non-uniform contact with the connector head
Solution Approach 1:
The patent resolves this contradiction by using asymmetry in the preliminary outer contour design. The non-circular preliminary outer contour is specifically configured so that when radially directed deformation forces are applied, the disc body deforms in a controlled manner to achieve a circular final outer contour. This asymmetric preliminary shape ensures that the deformation process simultaneously creates the oval/elliptical inner contour for captive fixation while maintaining uniformity of the outer contour for complete connector head contact.
Solution Approach 2:
The patent applies parameter changes by utilizing plastic deformation to permanently alter the geometric parameters of the disc body. The radially directed deformation forces change the inner contour from circular to oval or elliptical for captive fixation, while the non-circular preliminary outer contour is transformed into a circular final outer contour, ensuring uniform contact with the connector head. This controlled parameter transformation resolves the contradiction between captive fixation and outer contour uniformity.
3Ease of manufacture
If a circular preliminary outer contour is used, then the disc body can be easily manufactured, but radial deformation forces cannot be effectively introduced to create the desired non-circular inner contour for captive securing
Solution Approach 1:
The patent resolves this contradiction by introducing asymmetry through the non-circular preliminary outer contour. This non-circular shape provides effective engagement surfaces for introducing radially directed deformation forces. When these forces are applied, they effectively deform the disc body to create the oval or elliptical inner contour necessary for captive securing on the connector shank, while the deformation process simultaneously transforms the non-circular outer contour into a circular final contour.
4Reliability
If the disc body is deformed radially inward to reduce the through-hole size for captive securing, then the disc cannot fall down from the connector shank, but the outer contour distortion prevents uniform contact with the connector head
Solution Approach 1:
The patent resolves this contradiction by using asymmetry in the preliminary outer contour design. The non-circular preliminary outer contour is specifically configured to allow radially directed deformation forces to effectively deform the disc body inward, creating the oval or elliptical inner contour that prevents disc displacement. Simultaneously, this asymmetric preliminary shape ensures that the deformation process transforms the outer contour into a circular final contour, maintaining uniform contact with the connector head.
Solution Approach 2:
The patent implements preliminary action by pre-configuring the non-circular preliminary outer contour before deformation. This preliminary asymmetric shape is designed to guide the radial deformation process, ensuring that when forces are applied to reduce the through-hole size for captive securing, the outer contour is simultaneously transformed into a circular shape that ensures uniform connector head contact.
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 method provides a simple, cost-effective, and process-reliable means to securely fix the disc on the connector shank, ensuring uniform axial contact and reliable sealing, even under varying dimensional conditions, and allows for uniform handling and storage of the connection unit as a subassembly.
Implementation Method 1
the inner contour of the disc body in the state of the disc in which it is seated on the connector shank and starting from a preliminary inner contour which permits the prior sticking of the disc onto the connector shank is reshaped by way of plastic reshaping of the disc body into a final inner contour which effects a captive fixed holding of the disc on the connector shank
Implementation Method 2
the plastic reshaping of the annular disc body which creates the final inner contour of the annular disc body being carried out by way of radial deformation forces being introduced into the outer peripheral surface which has the preliminary outer contour, of the disc body which is seated on the connector shank
Implementation Method 3
ensuring uniform axial contact and reliable sealing
Data Source
AI summary
A method for producing a connection unit (1) which has a connector with a connector shaft (6) and a disc (3) which is captively arranged on the connector shaft (6). The disc (3) has an annular disc body (23), the inner contour (33) and outer contour (34) of which have been produced by a plastic deformation of the disc body (23). The inner contour (33) is shaped such that the disc body (23) is fixed on the connector shaft (6). At the same time, the originally non-circular outer contour (34) is shaped so as to be at least substantially circular. The deformation process is carried out by introducing radial deformation forces into the outer circumferential surface (27) of the disc body (23).