Integrally Formed King Pile Interlocks for Combined Wall Systems
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Solution Overview
Problem
Traditional king piles for combined wall systems are heavy and complex due to the need for metal interlock connectors that run the entire length of H-beams, complicating fabrication and increasing weight, which affects their strength and efficiency.
Innovation Solution
The design of a king pile with integrally formed king pile interlocks on rectangular flanges and a web, eliminating the need for separate interlock connectors by forming the interlocks during hot-rolling, resulting in a stronger, lighter structure with fewer weak points, and allowing for customizable dimensions and configurations to optimize material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If separate metal interlock connectors are used to connect H-beams and sheets, then the connection strength is improved, but the overall weight and fabrication complexity increase
Solution Approach 1:
The patent merges the interlock connector and the H-beam into a single integrated component. The interlocks are formed as integral parts of the H-beam through hot-rolling, eliminating the need for separate connectors. This reduces fabrication complexity while maintaining connection strength through direct structural integration.
Solution Approach 2:
The patent extracts the interlock functionality from the separate connector and integrates it directly into the H-beam structure. By forming interlocks as integral features of the H-beam itself, the design eliminates the need for additional connector components while preserving the connection function.
2Reliability
If separate metal interlock connectors run the entire length of H-beams, then the connection reliability is improved, but the weight of the king pile increases
Solution Approach 1:
The patent combines the H-beam and interlock connectors into a single integrated structure. The interlocks are formed as integral features of the H-beam through hot-rolling, eliminating the need for separate connectors that would add weight. This integration maintains connection reliability while reducing overall weight.
Solution Approach 2:
The patent changes the manufacturing process from assembling separate components to hot-rolling the H-beam with integrated interlocks. This parameter change in the fabrication process enables the interlocks to be formed as integral features, reducing material usage and weight while maintaining connection reliability.
3Strength
If separate interlock connectors are welded to H-beams, then the assembly strength is improved, but the manufacturing time and complexity increase
Solution Approach 1:
The patent applies preliminary action by forming the interlocks as integral features of the H-beam during the hot-rolling process, before assembly. This eliminates the need for subsequent welding operations, reducing manufacturing time and complexity while maintaining assembly strength through direct structural integration.
Solution Approach 2:
The patent merges the H-beam fabrication and interlock formation into a single hot-rolling process. This integration eliminates separate welding steps, improving manufacturing efficiency while maintaining the strength of the connection through integral structural design.
4Strength
If traditional H-beam design with separate connectors is used, then the structural integrity is maintained, but the material efficiency decreases
Solution Approach 1:
The patent merges the H-beam and interlock connectors into a single integrated component formed through hot-rolling. This integration eliminates redundant material from separate connectors and welding, improving material efficiency while maintaining structural integrity through direct structural integration.
Solution Approach 2:
The patent changes the manufacturing approach from assembling separate components to hot-rolling an integrated structure. This parameter change enables more efficient material utilization by forming interlocks as integral features, reducing total material consumption while preserving structural integrity.
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 approach reduces unnecessary weight and complexity, providing a more efficient and cost-effective solution for combined wall systems by eliminating the need for additional manufacturing steps and allowing for tailored specifications to meet specific design requirements, enhancing structural support and material efficiency.
Implementation Method 1
formed integrally therewith... formed during hot-rolling
Data Source
AI summary
A king pile for a combined wall system includes a first flange, a second flange, and a web. The first flange has a first flange body that is a generally rectangular plate having a first edge, a second edge, and a face. A first king pile interlock is formed integrally with the first flange body at the first edge, and a second king pile interlock is formed integrally with the first flange body at the second edge. The king pile includes a second flange having a second flange body, the second flange body being a generally rectangular plate having a face. The king pile also includes a web. The web may be a generally rectangular plate that is coupled to the face of the first flange body and the face of the second flange body. The first flange, second flange, and web may be formed separately and coupled by welding.