Connector assembly
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Solution Overview
Problem
Existing methods for connecting objects, such as wooden beams in a mailbox post, are prone to damage when subjected to significant forces, as they lack flexibility to absorb and distribute such forces effectively, leading to potential damage to the objects and the connecting system.
Innovation Solution
A fastener assembly comprising a spring, a first threaded stud device, a second threaded stud device, and a rigid shear pin, which allows the objects to move relative to each other when a threshold force is applied, preventing damage by breaking the shear pin and maintaining a flexible connection thereafter, with washers and a retention clip to manage force distribution and shear pin retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid fasteners (nails, bolts, screws) are used to connect objects, then the connection strength is improved, but the system becomes vulnerable to damage when subjected to high forces
Solution Approach 1:
The connector assembly transitions from a static rigid connection to a dynamic system that can adapt its state. The shear pin acts as a mechanical fuse that transitions from intact (rigid connection) to broken (flexible connection) based on applied force, allowing the system to dynamically respond to loading conditions and protect objects from damage.
Solution Approach 2:
The connector assembly is divided into distinct functional components: the shear pin (sacrificial element), the spring (flexible element), and the threaded stud devices (mounting elements). This segmentation allows each component to perform its specific function - the shear pin provides initial rigidity, while the spring provides flexibility - and enables easy replacement of the shear pin after it breaks.
2Object-affected harmful factors
If a flexible connection is used to allow movement under force, then damage is prevented, but the connection strength under normal conditions is reduced
Solution Approach 1:
The system dynamically switches between rigid and flexible states based on applied force. The shear pin maintains rigidity during normal operation, while automatically transitioning to a flexible state (via spring) when the shear pin breaks under excessive force, thus providing both strength and damage prevention.
Solution Approach 2:
The shear pin acts as an intermediary sacrificial element that absorbs the harmful effect of excessive force. It mediates between the rigid connection requirement and the flexibility need by breaking first, allowing the spring to then provide the necessary flexibility to prevent damage to the connected objects.
3Reliability
If a sacrificial element (shear pin) is used to protect the system, then reliability is improved, but the device complexity increases
Solution Approach 1:
The sacrificial function is extracted into a separate, replaceable shear pin component rather than being integrated into the main connector structure. This extraction simplifies the overall system by making the protective function modular and easily replaceable, reducing the complexity of maintenance while improving reliability.
Solution Approach 2:
The shear pin is designed as a inexpensive, replaceable component that is intentionally designed to fail first. This disposable element protects more valuable components from damage, and its low cost and simple replacement procedure offset the increased assembly complexity by enabling easy maintenance.
4Object-affected harmful factors
If the shear pin is designed to break at a threshold force, then object protection is achieved, but the precision of force threshold control becomes critical
Solution Approach 1:
The force threshold is controlled by changing the physical parameters of the shear pin (material properties, cross-sectional area, length). By adjusting these parameters, the break force can be precisely tailored to the specific application requirements, enabling accurate control of the protection threshold while maintaining manufacturing feasibility.
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 assembly effectively prevents damage to connected objects by allowing relative movement under high forces while maintaining a secure connection under standard conditions, ensuring the mailbox post remains functional and facilitating easy replacement of the shear pin when it breaks.
Implementation Method 1
a spring (20)... allows the objects to move relative to each other when a threshold force is applied... maintaining a flexible connection thereafter
Implementation Method 2
a rigid shear pin (40)... preventing damage by breaking the shear pin... allowing relative movement under high forces
Implementation Method 3
a first threaded stud device (15)... a second threaded stud device (25)... washers and a retention clip to manage force distribution
Data Source
AI summary
A fastener assembly may have a spring, a bolt, a stud, an end-piece, and a shear pin. In one embodiment of the invention, the bolt has (a) a shaft engaged with a first end of the spring, (b) a head, and (c) an internally-facing surface defining a passageway that extends through the bolt head and the bolt shaft. The stud has (a) a first end and (b) a second end, and the first end of the stud is engaged with a second end of the spring. The stud may include an internally-facing surface defining a hole that extends from the first end toward the second end of the stud. The end-piece, which may be a nut or an anchor, is engaged with the second end of the stud. Part of the shear pin resides in the passageway of the bolt, and a different part of the shear pin engages the stud. Also, the shear pin may include a slot on an end of the shear pin that may be used to remove a portion of the shear pin from the stud after the shear pin breaks.