Integrally Formed Connector Joints for Structural Members
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Solution Overview
Problem
There is a need for efficient and integrally formed connection methods between structural members formed by different manufacturing processes, aiming to minimize manufacturing steps and eliminate the use of separate fasteners.
Innovation Solution
The integration of specifically shaped connector portions on structural elements that can engage with each other, potentially using adhesives, to form structural members without the need for additional fasteners, where the connector portions can include projections, openings, and various shapes such as dovetail joints, and can be flexible or rigid, and may utilize adhesives that activate upon exposure to stimuli.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If separate fasteners are used to connect structural members, then connection strength can be achieved, but device complexity and manufacturing steps increase
Solution Approach 1:
The connector portion is integrally formed with the structural member itself, merging the connection function into the member rather than using separate fasteners. This eliminates the need for additional components and manufacturing steps while maintaining connection strength through the integrated design
2Device complexity
If integrally formed connectors are used to minimize manufacturing steps, then device complexity is reduced, but adaptability to different manufacturing processes is limited
Solution Approach 1:
The connector portion is designed with universal geometric features (protrusions, recesses, dovetail joints) that can be adapted to multiple manufacturing processes including pultrusion, extrusion, and molding. This allows the same integral connector design to work across different manufacturing methods while minimizing manufacturing steps
3Strength
If adhesive is applied to connector portions, then connection strength is improved, but manufacturing complexity increases
Solution Approach 1:
The connector portions are pre-formed with geometric features during the primary manufacturing process, and adhesive application is simplified to just the connector surfaces. This preliminary formation of mechanical interlocking features reduces the complexity of adhesive application while maintaining high connection strength through combined mechanical and chemical bonding
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
This solution enables strong and efficient connection of structural members formed by different processes, reducing manufacturing steps and eliminating the need for separate fasteners, while allowing for versatile applications in various industries such as construction and automotive.
Implementation Method 1
The connector portion may be contacted with an adhesive to improve connection between the first and second element
Data Source
AI summary
A structural member comprising an integrally formed connector portion on two or more elements for forming the structural member, wherein a first connector portion on a first element is shaped to engage a second connector portion on a second element.