Interlocking Weldless Connection for Dissimilar Metal Components
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Solution Overview
Problem
Conventional methods for connecting steel and aluminum components, such as in vehicle trailers, face challenges due to difficulties in reliable welding and subsequent failure under stress and environmental conditions, leading to loose connections and potential corrosion.
Innovation Solution
A weldless connection system using a plate with a curved edge that engages a recess in one component and is secured with mechanical fasteners to another component, allowing for strong and durable attachment without welding, accommodating different metals like steel and aluminum.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to connect steel and aluminum components, then initial connection strength is achieved, but connection reliability deteriorates over time due to weld failure and corrosion
Solution Approach 1:
The patent replaces the welding process (thermal/chemical joining) with a mechanical fastening system consisting of a plate, curved edge, recess, and fastener. This mechanical substitution eliminates the inherent problems of weld failure and corrosion while maintaining strong initial connection between dissimilar metal components.
Solution Approach 2:
The plate with curved edge acts as an intermediary component between the steel component and aluminum component. This intermediate element provides a mechanical interface that accommodates the challenges of joining dissimilar metals without direct welding, thereby improving long-term connection reliability.
2Ease of operation
If conventional mechanical fasteners (U-bolts) are used to connect steel and aluminum components, then ease of assembly is achieved, but connection stability deteriorates under stress and vibration
Solution Approach 1:
The curved edge of the plate is received within a recess, creating an interlocking geometry that prevents loosening under vibration and stress. This curved-recess configuration provides mechanical interlocking that maintains connection stability while preserving ease of assembly through simple fastener insertion.
Solution Approach 2:
The recess in the component receives the curved edge of the plate, creating a nested configuration where one element fits within a cavity of another. This nesting provides mechanical interlocking that prevents loosening while maintaining assembly simplicity.
3Strength
If welding is used to join metal components, then initial connection strength is achieved, but harmful effects increase due to accelerated corrosion from sacrificial anode effect
Solution Approach 1:
By replacing welding with a mechanical fastening system, the patent eliminates the electrochemical conditions that cause sacrificial anode corrosion. The mechanical connection does not create galvanic cells, thereby preventing accelerated corrosion while maintaining strong initial connection.
Data Source
AI summary
A weldless connection for connecting two components together, including first and second components having respective first faces which are disposed in flush engagement with each other, and having respective second faces which are planar and are substantially aligned with each other along a same plane, and a plate which is disposed so as overlap portions of the aligned second faces of the components. One edge of the plate is curved into a hook shape, a recess is formed into the second face of the first component and receives the curved edge of the plate therein for connecting the plate to the first component while permitting some relative movement between the plate and first component, and a portion of the plate which overlaps the second face of the second component is fixed thereto.