Mechanically interlocking frame assemblies
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Solution Overview
Problem
Existing structural frame assemblies using threaded fasteners often loosen over time due to vibration and load-induced bolt elongation, leading to misalignment and distortion of rails, making precise assembly challenging and prone to skewing.
Innovation Solution
The structural frame assembly features joints with mechanical interfaces that automatically self-align during tightening, using bolts that angularly intersect the joint interface, reducing looseness and distortion by providing multi-axial tightening and transverse compression of rails, allowing components to maintain precise alignment under load and vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If threaded fasteners are used to connect rails, then assembly is simple and components can be easily joined, but joints loosen over time due to vibration and load-induced bolt elongation
Solution Approach 1:
The patent changes the geometric parameter of the fastener by using an angled configuration (e.g., 45 degrees from perpendicular) instead of the conventional perpendicular orientation. This angular parameter change allows the fastener to simultaneously engage both rails at the joint, creating a mechanical interlock that prevents loosening while maintaining ease of assembly through simple insertion and tightening motions.
Solution Approach 2:
The patent transitions from a single-direction (perpendicular) fastener to a multi-directional (angled) fastener that engages rails in multiple spatial dimensions. The angled fastener creates force components in both radial and longitudinal directions, providing stability against vibration and load-induced elongation while preserving assembly simplicity.
2Ease of operation
If bolts extend orthogonally through joints, then assembly procedure is straightforward, but components can freely pivot and move with respect to each other
Solution Approach 1:
The patent modifies the orientation parameter of the bolt from orthogonal (90 degrees) to an angled configuration (e.g., 45 degrees). This parameter change transforms the bolt's function from merely fastening to simultaneously aligning and mechanically interlocking components, eliminating free pivot movement while keeping the assembly procedure intuitive through consistent angular insertion.
Solution Approach 2:
The angled bolt serves multiple functions simultaneously: it fastens the joint, aligns the rails precisely, prevents pivoting movement, and provides mechanical interlocking. This multi-functionality achieves both ease of operation and manufacturing precision without requiring separate alignment procedures or specialized skills.
3Strength
If threaded fasteners are tightened to secure joints, then connection strength increases, but rails become distorted and flared out at joints
Solution Approach 1:
The patent changes the geometric parameter of the fastener from perpendicular to angled (e.g., 45 degrees). This angular parameter change redirects the tightening force to act more axially along the rail rather than radially outward, maintaining connection strength while minimizing the flaring and distortion of the rail at the joint location.
Solution Approach 2:
The asymmetric angled configuration of the fastener creates a non-uniform force distribution that favors axial compression of the joint over radial expansion of the rail. This asymmetric geometry inherently prevents the symmetric flaring out that occurs with perpendicular fasteners, preserving rail shape integrity while achieving strong connections.
Data Source
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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.