Connecting Element With Folded-Out Legs For Profile Rails

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Solution Overview

Problem

Existing connecting elements for profile rails and profiles require significant material and result in high dead weight and manufacturing costs due to conventional design methods.

Innovation Solution

The connecting element features legs formed by folding out flat pieces from the web, reducing material usage and weight while maintaining stability, with the folded-out surface pieces connected via edge strips, allowing for a more efficient and cost-effective production process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional connecting elements are designed with solid legs and web structure, then connection stability is ensured, but material usage and dead weight increase

Engineering Contradiction:

Improveconnection stabilityVSAvoiddead weight of connecting element

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The web of the connecting element is designed with free spaces instead of being completely solid, creating a porous-like structure that reduces material usage and weight while preserving the necessary structural integrity for reliable connections

Inventive Principle:

Principle #31Porous materials

2Weight of stationary object

If material is removed from the web to reduce weight, then dead weight and manufacturing costs decrease, but structural stability may be compromised

Engineering Contradiction:

Improvedead weight of connecting elementVSAvoidconnection stability

Core Design Contradiction:

Weight of stationary objectVSReliability

Solution Approach 1:

The web is designed with non-uniform thickness and strategic free spaces, concentrating material where structural support is most needed while removing material from less critical areas, achieving weight reduction without compromising overall stability

Inventive Principle:

Principle #3Local quality

3Quantity of substance

If flat pieces are folded out from the web to form legs, then material usage and manufacturing costs are reduced, but the complexity of the forming process increases

Engineering Contradiction:

Improvematerial usageVSAvoidforming process complexity

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The flat pieces intended to become legs are pre-positioned and integrated into the web structure during the forming process, allowing them to be folded out as part of the initial forming operation rather than requiring separate attachment steps later

Inventive Principle:

Principle #10Preliminary action

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 design reduces material and manufacturing costs while ensuring a reliable connection of profile rails, eliminating unnecessary waste and maintaining sufficient stability for secure connections.

Implementation Method 1

at least one of the legs comprises a flat piece of the base part that is folded out of the web to form a free space

Methodology Applied

Scientific EffectFolding: Folding

Data Source

PatentEP2681375B1Connecting element and method of manufacturing

Publication Date: 2016.01.06 PROTEKTORWERK FLORENZ MAISCH GMBH & CO KG

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AI summary

A connecting element for connecting profile rails and/or profiles of various shape comprises a planar base part which comprises a central web and two lateral limbs which are angled with respect to the web. At least one of the limbs comprises a base part surface section slung out from the web.