Frame Section With Crossbar Recesses For Connection Stability
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Solution Overview
Problem
Existing frame parts, particularly cantilevered gates and fences, suffer from structural instability and loosening due to high dynamic and static loads, leading to fractures and material failure over time, with existing connection methods being either costly, time-consuming, or lacking in long-term stability and resilience.
Innovation Solution
A frame part design featuring a crossbar element that extends partially through material recesses in the upper and lower chord elements, with a beveled longitudinal end that is guided and secured without deformation, allowing for reliable welding or screwing connections on the side facing away from the crossbar, enhancing mechanical stability and resistance to distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional welding or screwing connections are used to join chord elements and crossbar elements, then the frame part can be assembled, but the connections loosen over time due to high dynamic and static loads
Solution Approach 1:
The connection system is divided into multiple functional zones: the crossbar element is segmented into a first end region (with engagement protrusion) and a second end region (for welding/screwing), while the chord element has distinct first and second regions with different connection functions. This segmentation allows each zone to optimize for its specific purpose, preventing load transfer that causes loosening.
Solution Approach 2:
The engagement protrusion on the crossbar element acts as an intermediary mechanical feature that inserts into a receiving recess in the chord element. This intermediary structure provides a stable load-bearing interface that prevents direct stress transfer to the welding or screwing connections, eliminating the loosening problem over time.
2Reliability
If mechanical deformation is applied to tubular elements for secure fixation, then connection stability improves, but the process becomes time-consuming and expensive
Solution Approach 1:
The engagement protrusion and receiving recess are pre-formed during the manufacturing of the crossbar and chord elements, respectively. This preliminary action eliminates the need for time-consuming mechanical deformation operations during assembly, while still providing secure fixation through the precision-fit engagement features.
3Reliability
If tubular elements are deformed for connection, then secure fixation is achieved, but manufacturing precision requirements increase significantly
Solution Approach 1:
The engagement protrusion on the crossbar element is designed to self-align with the receiving recess in the chord element during assembly. The geometric configuration of these features provides automatic positioning and alignment, eliminating the need for high-precision manual alignment or complex adjustment procedures.
4Reliability
If adapters are used to enable screw connections in tubular elements, then connection stability improves, but the device complexity and cost increase
Solution Approach 1:
The engagement protrusion and receiving recess are integrated directly into the crossbar and chord elements during their manufacturing. This merging of the engagement features with the structural elements eliminates the need for separate adapter components, reducing device complexity while maintaining connection stability.
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3c
AI summary
The frame member has an upper strap element (1), a lower strap element (2) and a cross bar element (3) beveled at a longitudinal axial end (LE). The cross bar element is connected to a corresponding strap element at the longitudinal axial end. The cross bar element is arranged in deformation free material recesses (5) arranged at the sides (7) of the strap elements facing away from the cross bar element. An independent claim is also included for a method for manufacturing a frame member by using laser.