Interlocking Frame Joints With Angular Self-Aligning Fasteners
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Solution Overview
Problem
Structural frame assemblies using threaded fasteners often experience joint looseness due to vibration, load-induced bolt elongation, and thread wear, leading to misalignment and distortion of rails, making precise assembly challenging and prone to skewing during use.
Innovation Solution
The design incorporates angularly intersecting bolts and nuts with angled abutment walls and shoulders, allowing for self-alignment and multi-axial tightening, which compresses rails and maintains precision without manual adjustment, reducing looseness and distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If threaded fasteners are used to connect rails, then the frame assembly can be assembled and disassembled, but the joints loosen over time due to vibration and load-induced bolt elongation
Solution Approach 1:
The fastener system transitions from a static orthogonal connection to a dynamic angular intersection that allows controlled movement and self-adjustment. The angled intersection (non-90 degrees) enables the fastener to accommodate load-induced elongation and vibration while maintaining joint integrity, resolving the contradiction between assemblability and joint stability.
Solution Approach 2:
The invention changes the geometric parameter of fastener intersection from orthogonal (90 degrees) to angular (non-90 degrees). This parameter change allows the fastener system to compensate for bolt elongation and thread wear by distributing stresses differently, thereby maintaining joint stability over time while preserving ease of assembly.
2Ease of operation
If bolts extend orthogonally through joint components, then assembly is simplified, but components pivot and move freely causing misalignment
Solution Approach 1:
The invention introduces asymmetry by using angularly intersecting fasteners instead of symmetric orthogonal fasteners. This asymmetric configuration restricts pivotal movement and prevents free rotation of joint components, thereby achieving precise alignment while maintaining relatively simple assembly procedures.
Solution Approach 2:
The fastener intersection angle adds a dimensional constraint that prevents movement in certain directions. By changing from orthogonal (single-plane) to angular (multi-plane) intersection, the system gains control over component positioning in multiple dimensions, achieving precision without complex alignment procedures.
3Strength
If threaded fasteners are tightened to secure joints, then connection strength increases, but rails distort by flaring outward at joints
Solution Approach 1:
The invention applies local quality by using angularly intersecting fasteners that distribute clamping forces differently across the joint. This localized force distribution prevents the concentrated outward flaring that occurs with orthogonal fasteners, maintaining rail geometry integrity while achieving strong joint connections.
Solution Approach 2:
Instead of using orthogonal fasteners that push rails outward, the invention inverts the approach by using angular fasteners that pull rails inward or apply compressive forces. This inverted force direction prevents rail flaring and distortion while maintaining connection strength.
4Reliability
If joints are pinned or welded to prevent loosening, then joint stability increases, but assembly complexity and skill requirements increase
Solution Approach 1:
The angularly intersecting fastener system is self-aligning and self-adjusting. It automatically compensates for load-induced elongation and vibration without requiring external intervention such as pinning or welding. This self-service mechanism maintains joint stability while keeping the assembly process relatively simple and accessible to less skilled workers.
Data Source
AI summary
A structural frame assembly is provided that includes mechanically interlocking components. The frame assembly has rails that interconnect with each other at joints that include brackets that engage the rails and nuts that are held in cavities of the rails that are connected to slots that extend through outer surfaces of the rails. Bolts may extend angularly through bores of the bracket and the slots of the rails to operatively engage a nut being held in the cavity. Tightening the bolts may draw the nut angularly through the cavity in a manner that automatically self-aligns the brackets and rails to establish precise joints.