Monolithic Steel-Aluminium Roof Bracket Design
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Solution Overview
Problem
Existing assembly brackets used in connecting hollow sections for roofing elements are prone to breakage due to poor quality welds, which can lead to the collapse of roof structures, especially under high bending forces.
Innovation Solution
A monolithic reinforcing section made of steel, curved and overmoulded with cast aluminium, forms the assembly bracket, eliminating the risk of joint failure and providing a cylindrical external shape for interlocking with hollow sections, with threaded holes closer to the ends for enhanced resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welded steel arms are used to form assembly brackets, then manufacturing simplicity is maintained, but mechanical strength and reliability deteriorate due to weld breakage under bending forces
Solution Approach 1:
The patent merges two separate steel arms into a single monolithic reinforcing section. This eliminates the weld joint between arms while maintaining the bracket's structural function. The single-piece construction directly addresses the reliability issue by removing the weak welded connection point.
Solution Approach 2:
The patent creates a composite structure by overmoulding aluminium alloy onto the steel reinforcing section. This combines the high strength properties of steel with the corrosion resistance and aesthetic qualities of aluminium, achieving superior mechanical strength while protecting the steel core from rust.
2Reliability
If weld joints are used to connect steel arms, then ease of manufacture is improved, but reliability deteriorates due to manufacturing defects in welds
Solution Approach 1:
The patent merges two separate steel arms into a single monolithic reinforcing section. This eliminates the weld joint between arms while maintaining the bracket's structural function. The single-piece construction directly addresses the reliability issue by removing the weak welded connection point.
3Strength
If the fixing holes are positioned in the middle of the arms, then ease of assembly is improved, but mechanical strength deteriorates under bending forces
Solution Approach 1:
The patent applies local quality by positioning the fixing holes in specific zones near the ends of the arms rather than uniformly in the middle. This strategic placement creates local reinforcement areas that better resist bending moments while maintaining overall structural integrity.
4Reliability
If a monolithic reinforcing section is used instead of welded arms, then reliability is improved by eliminating weld joints, but manufacturing complexity increases
Solution Approach 1:
The patent merges two separate steel arms into a single monolithic reinforcing section. This eliminates the weld joint between arms while maintaining the bracket's structural function. The single-piece construction directly addresses the reliability issue by removing the weak welded connection point.
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 significantly enhances the mechanical strength and reliability of the assembly bracket, reducing the risk of breakage and ensuring structural integrity under high bending forces, particularly for angles greater than 160°.
Implementation Method 1
The overmoulding, preferably in cast aluminium, of this reinforcing section makes it possible to equalize a bending radius R of the latter and to give the arms 1, 2 of the assembly bracket an external shape adapted to the internal shape of the hollow sections
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The plate has two arms (1, 2) connected with each other at an obtuse angle (alpha ). Each arm is constituted of a monolithic reinforcement section (3) made up of steel, which is curved at center and over mould by an material (4) e.g. aluminum, such that the reinforcement section provides an external shape to the arm appropriated for the fitting of the arms in hollow sections of a crest structure. An independent claim is also included for a crest structure for a roof unit.