Inclined Tube Coupling Structure for Secure Tool-Free Assembly
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Solution Overview
Problem
Existing couplers for tubes are costly, heavy, and unsuitable for special-shaped tubes, requiring special tools for installation and removal.
Innovation Solution
A tubular end-to-end coupling structure with inclined surfaces and misaligned occlusal teeth, using screws through oblique sidewall holes and threaded protrusions for connection, allowing conventional tools for installation and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional CNC turning and milling processes are used to produce couplers, then the couplers have high strength and reliability, but the cost is high and the weight is heavy
Solution Approach 1:
The coupler is divided into multiple modular components including a body portion, end portions with internal threads, and separate cap portions. This segmentation allows each component to be optimized independently and assembled to achieve the required strength while reducing overall weight compared to traditional monolithic CNC-machined couplers.
Solution Approach 2:
The end portions are nested within the body portion through internal threading, and cap portions are screwed onto the external threads of the end portions. This nested configuration eliminates the need for heavy welding or complex joining mechanisms while maintaining structural integrity and reducing weight.
2Ease of manufacture
If traditional coupler designs are used, then the structure is simple to manufacture, but they are not suitable for special-shaped tubes and have high cost
Solution Approach 1:
The coupler body portion is designed with a universal internal geometry that can accommodate various tube shapes and dimensions. The end portions can be configured with different external thread patterns to match different tube types, allowing a single basic coupler design to serve multiple tube configurations including special shapes, thereby increasing versatility without complicating the core manufacturing process.
Solution Approach 2:
The internal threading and basic geometry of the body portion are pre-formed using standard manufacturing processes. This preliminary action allows the coupler to be adapted to different tube shapes by simply changing the end portion configurations or internal thread patterns, rather than requiring complete redesign and re-manufacturing for each tube type.
3Ease of operation
If conventional couplers are used, then the installation is straightforward, but special tools are required for installation and removal
Solution Approach 1:
The coupler incorporates external threads on the end portions that can be directly engaged with standard fastening tools or pipe threads. This self-threading design allows installation and removal using conventional wrenches or screwdrivers without requiring specialized coupling tools, making the operation straightforward while eliminating the need for complex tool sets.
4Reliability
If the coupler uses inclined surfaces and occlusal teeth for connection, then the coupling is secure and prevents loosening, but the manufacturing precision requirements increase
Solution Approach 1:
The occlusal teeth are designed with asymmetric profiles where the inclined surfaces have specific angles optimized for load distribution. This asymmetric geometry creates a self-locking effect where the teeth naturally engage in a locked position under load, preventing loosening without requiring extremely tight manufacturing tolerances, as the geometry itself provides the locking mechanism.
Solution Approach 2:
The inclined surfaces of the occlusal teeth are designed with built-in compliance that allows for minor misalignments and variations in manufacturing. The gradual inclination of the surfaces distributes contact stresses and accommodates small dimensional variations, providing a cushioning effect that maintains reliable coupling even when manufacturing precision is not extremely high.
Data Source
AI summary
A tubular end to end coupling structure includes a first inclined tube having a first inclined surface, a second inclined tube having a second inclined surface, and a coupling structure. The first inclined tube and the second inclined tube are connected by the coupling assembly. The coupling assembly includes a plurality of first convex teeth, tooth grooves, second convex teeth and second tooth grooves. The first convex teeth are engaged in the second tooth grooves, and the second convex teeth are engaged in the first tooth grooves. A first protrusion having a through hole is formed at the first inclined surface, a second protrusion having a through hole is formed at the second inclined surface, a first sidewall hole is formed in the first inclined tube, and a second sidewall hole is formed in the second inclined tube.