One-Piece Clamping Element Steps for Roof Rafter Fastening
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Solution Overview
Problem
Existing fastening devices struggle to achieve high holding forces on mounting bases due to limitations in the design and production methods of clamping and counter-clamping elements.
Innovation Solution
A method involving the production of clamping and counter-clamping elements from one-piece metal bodies using machining processes, where steps are machined with constant heights along the longitudinal direction to enhance clamping force, and through holes or grooves are incorporated for additional attachment options, allowing for longer clamping lengths and increased holding capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If clamping elements are produced from one-piece metal bodies with long steps extending along the longitudinal direction, then clamping force and holding capability are improved, but manufacturing complexity and material consumption increase
Solution Approach 1:
The clamping element is divided into multiple modular components (clamping element proper, counter-clamping element, mounting base) that can be manufactured separately and assembled together. This segmentation allows each component to be optimized independently, reducing overall manufacturing complexity while maintaining the one-piece construction benefit for force distribution.
Solution Approach 2:
The patent specifies precise geometric parameters for the steps (height, length, spacing) and material properties (metal body characteristics) to optimize clamping force. By standardizing these parameters across modular components, the invention achieves high holding capability through parameter optimization rather than increased complexity.
2Force
If steps are machined with constant heights extending over at least 30% of the total distance between ends of clamping element, then holding force on mounting base is improved, but manufacturing time and material removal increase
Solution Approach 1:
The steps extend over at least 30% of the total distance between ends of the clamping element, which is sufficient to achieve the required holding force without the need for excessive material removal. This partial action approach provides the minimum necessary clamping surface area to achieve effective holding while minimizing manufacturing time and material waste.
Solution Approach 2:
The constant height parameter of the steps is optimized to provide sufficient holding force over the required 30% length. By carefully selecting this parameter, the invention achieves effective clamping with minimal material removal and manufacturing time.
3Adaptability or versatility
If through holes or grooves are incorporated in clamping element, then adaptability for different attachment methods is improved, but structural integrity and manufacturing precision requirements increase
Solution Approach 1:
The clamping element is designed with both through holes (for screw attachment) and grooves (for press-fit or welding attachment) as optional features, making it universally adaptable to different mounting methods. This multi-functionality allows the same basic component design to serve multiple attachment purposes while maintaining structural integrity through proper placement and dimensioning of these features.
Solution Approach 2:
The through holes and grooves are positioned at specific locations on the clamping element where they minimize impact on overall structural integrity. The local modifications are carefully designed to provide attachment functionality without compromising the strength and precision requirements of the main clamping structure.
Data Source
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AI summary
The invention relates, inter alia, to a method for manufacturing a fastening device (10) suitable for mounting on two roof rafters (20, 21), wherein in the method a mounting base (30) is manufactured which is telescopic and adjustable in length, and a clamping element (100) and a counter-clamping element (110) are manufactured which can be connected to each other in such a way that the clamping element (100) and the counter-clamping element (110) clamp a section of the mounting base (30) between them after the fastening device (10) has been mounted.According to the invention, the clamping element (100) and/or the counter-clamping element (110) is each made from a one-piece metal body, wherein steps (200) are formed on the inside of the clamping element (100) and/or the counter-clamping element (110), which or at least their step edges (201) bear against the mounting base (30) after the clamping element (100) and/or the counter-clamping element (110) has been mounted.