Friction-Increasing Connecting Element for Thin-Component Pre-Assembly
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Solution Overview
Problem
Existing friction-increasing connections for components with thicknesses of 0.8 mm or less face challenges in mechanical pre-assembly, as countersunk screws cannot be used, leading to incomplete contact and impaired torque transmission.
Innovation Solution
A connecting element with a metal substrate and hard particles fixed by a metallic binder layer, featuring extensions that can be bent down for secure fastening, allowing pre-assembly and ensuring complete contact without protrusion, thereby enhancing frictional engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If countersunk screws are used for pre-assembly of thin connecting elements (0.8 mm or less), then the connecting element can be mechanically fixed to the component, but the screw head cannot be sunk into the connecting element and would protrude from it, preventing complete contact with the second component and impairing torque transmission
Solution Approach 1:
The opening in the metal substrate is segmented into multiple parts by providing extensions that divide the opening into a central inner hole and surrounding outer regions. This segmentation allows different parts of the opening to serve different functions: the inner hole receives the screw shaft while the extensions provide bearing surfaces for the screw head, enabling complete contact without protrusion
Solution Approach 2:
The solution transitions from a two-dimensional flat opening to a three-dimensional structure with extensions protruding from the metal substrate. These extensions create additional spatial dimensions that allow the screw head to bear on the extensions rather than protruding from the connecting element, resolving the conflict between mechanical fixation and complete contact
2Reliability
If the metal substrate has extensions directed towards the inner hole, then the extensions can be bent down for secure fastening and complete contact, but the structural complexity of the opening increases
Solution Approach 1:
The opening structure is segmented into extensions and inner hole, where the extensions are simple protrusions from the metal substrate perimeter. This segmentation achieves complex functionality (secure fastening with complete contact) through relatively simple structural divisions rather than complex geometries
Solution Approach 2:
The extensions are designed to be bent down during the fastening process, using the fastening operation itself to create the secure connection. The structure serves its own fastening function through the bending action, eliminating the need for separate fastening mechanisms and reducing overall structural complexity
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 solution enables reliable pre-assembly and secure fixation of the connecting element, increasing the coefficient of static friction by up to a factor of 2 or 4, facilitating efficient torque transmission without design changes or weight penalties.
Implementation Method 1
hard particles, which are fixed on the metal substrate by means of a metallic binder layer
Implementation Method 2
the coefficient of static friction can be increased in frictional connections
Data Source
AI summary
The present disclosure relates to a connecting element and to a process for producing said connecting element. The present disclosure further relates to a connecting system and a device comprising said connecting element, and to a process for fixing said connecting element to a first component. The present disclosure further relates to the use of said connecting element and connecting system for friction-increasing connection of a first and a second component in energy generation, specifically in wind turbines and hydropower turbines, and in machine, plant, motor vehicle and aircraft construction.