Radially Intermediate Joint Using Deformable Insert Ring
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Solution Overview
Problem
Existing methods for joining components, such as welding and plastic flow joints, often compromise material properties or fail to provide sufficient shear strength, especially in applications with high axial loading, due to the use of materials with low yield strength.
Innovation Solution
A coaxial assembly using a deformable insert ring pressed into a groove with an arcuate geometry, allowing the insert ring to fill concave and convex portions, thereby locking components in both axial directions without requiring radial expansion, enabling the use of high-strength materials like heat-treatable steel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to join metal components, then the components are securely joined, but the heat affected zone reduces material hardness and adversely affects material properties
Solution Approach 1:
The patent replaces the thermal welding process with a mechanical cold-forming process. An intermediate ring is cold-formed and plastically deformed to fill grooves between components, creating a mechanical interlock joint without heat input. This substitution eliminates the heat affected zone while maintaining secure joining through mechanical interference and material flow into grooves.
2Ease of manufacture
If a plastic flow joint is used with a connecting ring of low yield strength material, then the ring can be easily deformed to fill grooves, but the joint lacks sufficient shear strength for high axial loading applications
Solution Approach 1:
The patent fundamentally changes the material parameter (yield strength) of the connecting ring from low strength materials (copper, brass, aluminum with yield strength ~50 MPa) to high strength materials (carbon steels with yield strength 250-1300 MPa). This parameter change enables the use of high-strength materials that can withstand high axial loading while still achieving adequate deformation through controlled groove geometry and forming processes.
Solution Approach 2:
The patent applies different geometric characteristics to different regions of the groove. The groove includes a tapered section with gradually increasing depth, creating varying local constraints on the connecting ring. This local variation in groove geometry allows controlled deformation in high-strength materials, enabling them to be formed into the groove structure without requiring uniformly low strength throughout the material.
3Ease of manufacture
If the groove has a straight geometry, then the insert ring can be easily pressed in, but the joint lacks locking in both axial directions and sufficient shear strength
Solution Approach 1:
The patent replaces the straight cylindrical groove geometry with an arcuate (curved) groove cross-section. This curvature creates a locked configuration where the deformed connecting ring material surrounds and interlocks with the groove walls in both axial directions. The arcuate geometry transforms the simple insertion process into a locking mechanism that provides bidirectional axial retention and enhanced shear strength through the curved material flow pattern.
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
The solution provides a high-strength joint with excellent shear strength in both axial directions, suitable for applications under high axial loading, without compromising material properties, and allows for the selection of materials based on required strength, optimizing joint performance.
Implementation Method 1
When the insert ring is pressed into the groove, it is deformed and adopts the shape of the arcuate section, such that material of the insert ring fills the concave portion and surrounds the convex portion
Implementation Method 2
the connecting ring is pressed and plastically deformed such that material of the ring flows into the grooves and recess
Data Source
AI summary
An assembly includes a first component joined to a second component by an intermediate joint. The first component has a first joining surface arranged coaxially and spaced in a juxtaposition around a second joining surface of the second component such that a groove is defined between the first and second joining surfaces. One of the first and second joining surfaces includes a concave portion and the other of the first and second joining surfaces has a convex portion radially opposite the concave portion, and the groove is formed by the convex and concave portions. The intermediate joint is formed by an insert ring pressed into the groove and deformed such that material of the insert ring fills the concave portion and surrounds the convex portion, and this locks the first and second components relative to each other in both axial directions.