Lattice Connector Joining for Stronger Interwoven Part Joints
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Solution Overview
Problem
Existing methods for securing two parts of a product together, such as hot stapling, rely on limited surface interaction, resulting in modest friction and adhesion forces, which are insufficient to withstand various forces and stresses effectively.
Innovation Solution
A manufacturing system that creates a connector with a lattice structure, where a force system applies pressure and optionally heat to interweave material within the lattice structure, securing the joint by distributing forces across a large number of structural members and elements, enhancing shear, tensile, friction, and adhesion strengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hot stapling is used to secure two parts together, then the joining process is quick and efficient, but the connection strength is limited due to restricted staple/part interaction
Solution Approach 1:
The connector is segmented into a lattice structure comprising multiple struts arranged in a geometric pattern, creating numerous discrete interaction points with the part material. This segmentation transforms a single-point connection into a distributed network of connections, simultaneously maintaining quick joining while dramatically increasing connection strength through multiple load-bearing pathways
Solution Approach 2:
The invention transitions from traditional surface-level stapling to a three-dimensional lattice structure that penetrates and interweaves with the part material. By adding the depth dimension and creating a volumetric engagement rather than a superficial one, the connector achieves both rapid attachment and enhanced strength through extended interaction volume
2Strength
If a lattice structure is used to increase connection strength, then the load-carrying capability is significantly increased, but the device complexity increases
Solution Approach 1:
The lattice structure serves multiple functions simultaneously: it provides mechanical interlocking with the part material, distributes applied loads across numerous struts, creates friction through surface contact, and enables adhesion through interweaving. This multi-functionality allows a single structural design to address multiple performance requirements without adding separate components, thereby managing complexity while achieving superior load-carrying capability
3Strength
If material is forced into the lattice structure to interweave and secure the joint, then friction and adhesion strengths are optimized, but the manufacturing process becomes more complex
Solution Approach 1:
The invention merges the connector formation and material interweaving into a single integrated operation. The connector is formed with the lattice structure and simultaneously forced into the part material, causing the material to flow into and interweave with the struts. This combining of operations achieves optimized friction and adhesion strengths while avoiding the need for separate manufacturing steps, thereby managing manufacturing complexity
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 lattice structure significantly increases the load-carrying capability of the joint by distributing forces over a large area, reducing stress and preventing product failure under various loads, while optimizing friction and adhesion strengths.
Implementation Method 1
A force system forces material into the lattice structure interweaving the material with the lattice structure to secure the joint
Implementation Method 2
A heating system may be included to heat the connector
Implementation Method 3
enhancing shear, tensile, friction, and adhesion strengths
Implementation Method 4
enhancing shear, tensile, friction, and adhesion strengths
Data Source
AI summary
Systems and methods for securing a product joint with a lattice structure. A system includes at least one fabricating system to create a connector with the lattice structure. A force system applies a force to the connector so that a material of the product flows into the lattice structure interweaving the material with the lattice structure to secure the joint by the lattice structure.