No-Weld Hinge Knuckle Connector for Pipe Fence Assembly
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Solution Overview
Problem
Traditional pipe fencing methods require welding, which is costly, time-consuming, and difficult to execute in adverse weather conditions, and the resulting fences are permanent and difficult to dismantle or reassemble.
Innovation Solution
A no-weld connector assembly using externally threaded attachment bolts and sleeves, or hinge knuckles, that can pivot up to ±28° to connect pipe rail or brace members to vertical posts without welding, allowing for easy installation and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to connect pipe rails to fence posts, then the fence structure strength is improved, but the construction cost and time increase significantly
Solution Approach 1:
The patent introduces a connector assembly as an intermediary component between the pipe rail and fence post. This connector includes a post mounting plate attached to the fence post, a rail mounting plate attached to the pipe rail end, and a hinge knuckle connecting both plates. The hinge knuckle acts as the mediator that joins the two structural elements, providing a strong connection without requiring welding operations.
Solution Approach 2:
The connection system is divided into separate modular components: the post mounting plate, rail mounting plate, and hinge knuckle can be manufactured independently and assembled on-site. This segmentation allows each component to be optimized for its specific function and enables quick assembly without welding, directly addressing the productivity concern while maintaining overall structural strength.
2Strength
If welding is used to connect pipe rails to fence posts, then the fence structure strength is improved, but the construction cost increases
Solution Approach 1:
The hinge knuckle serves as a mediator that replaces the welding process. Instead of using expensive welding equipment and skilled welders, the patent employs a mechanically simple hinge knuckle that can be installed with basic hand tools. This intermediary component eliminates the need for welding while maintaining structural integrity, thereby reducing construction costs.
Solution Approach 2:
The connector assembly uses simple, inexpensive metal plates and a hinge knuckle that can be manufactured at low cost. These components are designed to be replaced if needed, and their low individual cost allows for easy replacement without significant expense, addressing the construction cost concern.
3Strength
If welding is used to connect pipe rails to fence posts, then the fence structure strength is improved, but the ability to work in adverse weather conditions deteriorates
Solution Approach 1:
The hinge knuckle and mounting plates create a mechanical connection that does not rely on thermal processes like welding. This allows installation in wet, snowy, or cold conditions where welding would be unsafe or impossible. The mediator component enables the connection to be made through simple mechanical fastening rather than heat-based joining.
Solution Approach 2:
The patent replaces the thermal/mechanical welding process with a purely mechanical connection system using bolts, screws, or rivets to attach the mounting plates to the fence post and pipe rail. This substitution eliminates fire hazards and weather constraints associated with welding while maintaining structural strength through robust mechanical fastening.
4Strength
If welding is used to connect pipe rails to fence posts, then the fence structure strength is improved, but the ability to dismantle and reassemble the fence deteriorates
Solution Approach 1:
The connection is divided into separate removable components: the post mounting plate, rail mounting plate, and hinge knuckle can be detached from each other. This segmentation allows the fence to be dismantled by simply removing the fasteners connecting these components, without damaging the pipe rails or fence posts, enabling easy reassembly elsewhere.
Solution Approach 2:
The hinge knuckle provides a dynamic, reversible connection rather than a permanent weld. The mechanical fastening system allows the connection to be made and unmade multiple times, providing the flexibility to dismantle, transport, and reassemble the fence as needed while maintaining structural strength when assembled.
5Manufacturing precision
If fixed-angle connectors are used to connect pipe rails to fence posts, then the installation precision is improved, but the adaptability to varying terrain deteriorates
Solution Approach 1:
The hinge knuckle provides a dynamic connection that can accommodate various angles between the fence post and pipe rail. Instead of requiring precise pre-drilled holes at specific angles, the hinge mechanism allows the pipe rail to be positioned at different angles and then secured, providing both precision when needed and adaptability to varying terrain conditions.
Data Source
AI summary
A connector assembly and method for constructing a no-weld pipe fence, a no-weld fence end brace, or a no-weld fence corner brace. The connector assembly includes (a) a bolt, a threaded pin, or a hinge knuckle structure which is attachable to a fence post and (b) an attachment sleeve which can be slidably nested on the end of a pipe rail or brace member. The attachment sleeve is connectable to the bolt, threaded pin, or hinge knuckle structure in a manner which allows the pipe rail or brace member to be pivoted to a horizontal position or to any other desired angle on the fence post and then locked in place.