Captive Disc Fixation on a Connector Shaft With Circular Outer Profile
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Solution Overview
Problem
Existing connection units face challenges in securely and cost-effectively fixing a washer or disc on a connector shaft, particularly when dimensions are unfavorable, leading to issues with the washer not lying completely on the disk body, especially when a seal is intended.
Innovation Solution
A method involving a ring-shaped disc body with a preliminary non-circular outer contour that undergoes plastic deformation to form a final inner and outer contour, ensuring a secure fit on the connector shaft, allowing for a uniform axial contact and aesthetic alignment with the connector head.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the washer body is compressed from two diametrically opposed sides to create an oval or elliptical ring contour, then the washer is secured on the screw shank, but the screw head cannot rest completely on the washer body during intended use
Solution Approach 1:
The patent applies asymmetry by giving the washer body an oval or elliptical ring contour that is asymmetric relative to the circular screw shank. This asymmetric deformation of the washer body's inner circumferential surface allows it to be secured on the screw shank while maintaining proper contact with the screw head, resolving the contradiction between secure fixation and contact uniformity
2Reliability
If the washer body is plastically deformed radially inwards to reduce the through-hole size, then the disc is trapped securely on the connector shaft, but the outer contour deviates from circular shape affecting aesthetic alignment
Solution Approach 1:
The patent applies local quality by differentiating the deformation characteristics of different regions of the washer body. The inner circumferential surface is plastically deformed radially inwards to achieve captive locking, while the outer circumferential surface is simultaneously formed to maintain a substantially circular shape, ensuring both secure fixation and aesthetic alignment with the connector head
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 enables a reliable, cost-effective, and process-reliable captive fixation of the disc on the connector shaft, ensuring uniform handling and functional combination of the connector and washer, with the disc functioning as a washer or sealing disk, and providing a secure seal.
Implementation Method 1
the annular disk body is plastically deformed in such a way that the inner contour of the annular disk body, which deviates from a circular shape, is formed
Implementation Method 2
the plastic deformation of the annular disc body is carried out by introducing deformation forces radially into the outer circumferential surface of the disc body sitting on the connector shaft
Data Source
Figure 1~4
Figure 2~3
Figure 5~6
AI summary
The invention relates to 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). The invention additionally relates to a connection unit (1) which can be produced using the method.