Flange Connector Sinusoidal Legs Concrete
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Solution Overview
Problem
Existing flange connectors for precast concrete structures face challenges in being economical to manufacture, easy to position and stabilize during casting, providing a large welding area, accommodating slab alignment variations, being accessible for welding, resisting pull-out forces, and minimizing concrete cracking.
Innovation Solution
A flange connector design featuring a center plate with angled transition regions and sinusoidal projections on legs, which are embedded in concrete, allowing for enhanced welding accessibility and resistance to pull-out forces while maintaining consistent tensile strength and minimizing concrete cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the flange connector uses traditional straight legs embedded in concrete, then the manufacturing is simple, but the pull-out resistance is insufficient
Solution Approach 1:
The patent applies curvature by forming sinusoidal waves along the length of the legs. These curved undulations increase the surface area and create mechanical interlocking with the concrete, significantly improving pull-out resistance compared to straight legs. The curved geometry transforms the simple cylindrical leg into a wave-patterned structure that better resists extraction forces.
2Ease of operation
If the center plate is positioned perpendicular to the legs, then the structural alignment is simplified, but the welding accessibility is reduced
Solution Approach 1:
The patent introduces an angular dimension between the center plate and legs, positioning the center plate at an angle rather than strictly perpendicular. This angular orientation creates additional spatial dimensions for welder access while the transition region maintains the structural connection. The angled configuration allows welding approaches from multiple directions without compromising the structural integrity.
3Reliability
If the legs are positioned to accommodate reinforcing mesh, then the structural reinforcement integration is improved, but the positioning and stabilization during casting becomes more difficult
Solution Approach 1:
The patent segments the leg structure into distinct functional zones: embedded portions that interact with reinforcing mesh, transition regions with specific angular orientations, and exposed portions for welding. This segmentation allows each zone to be optimized independently - the embedded zones accommodate reinforcement while the transition zones maintain positioning stability during casting operations.
4Area of stationary object
If the flange connector uses a compact design, then the material usage is reduced, but the welding area is insufficient
Solution Approach 1:
The patent extends the welding area by utilizing angular orientations and transition regions that create additional exposed surface area on the center plate. Instead of simply increasing the plate size in one dimension, the angular configuration distributes the welding surface across multiple orientations, providing adequate welding area while maintaining a compact overall connector volume and material usage.
Data Source
AI summary
A flange connector is embedded in precast concrete structural member for use in joining adjacent concrete members together, wherein the flange connector is characterized by a center plate and legs extending back from each side of the center plate. Each of the legs is provided with projections extending from the top edge and bottom edge of the leg, in the same plane defined by the height and length of the leg. The projections extending from the top edge and the bottom edge of the leg may be mirror images of each other, so that the cross-sectional area of the leg is substantially the same over the portion of the leg with the projections. The legs of the flange connector may incorporate additional enhancements to increase the resistance to pull out, including a neck formed by notches in the top and bottom of each leg, adjacent the transition region extending from the center plate and one or more embossments creating a convex area on one side of each leg and a concave area on the opposite side of each leg.