Self-Interlocking Node Elements for Buckling-Resistant Lattice Joints
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Solution Overview
Problem
Traditional methods for assembling lattice structures, such as welding and bolting, are costly, labor-intensive, and compromise the strength of bars at their ends, often modeling bar ends as pinned instead of clamped, which reduces buckling resistance and increases material costs.
Innovation Solution
A kit and method for assembling lattice structures using self-interlocking elongated bars through hollow insertion channels in node elements, eliminating the need for axially displaceable screw bolts, gusset plates, or welding, and allowing for simple and fast installation without complex tools, while restraining translational and rotational movements to enhance buckling resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding or bolting is used to join bars with clamped ends, then buckling resistance is improved, but manufacturing cost and labor time increase significantly
Solution Approach 1:
The node element is designed to automatically clamp the bar ends between its contact side and coupling side when the bar is inserted through the hollow insertion channel. The bar itself serves as the clamping element by being compressed between the node's internal surfaces, eliminating the need for external welding or bolting operations. This self-clamping mechanism achieves clamped end conditions without requiring additional fastening operations or specialized tools.
Solution Approach 2:
The invention extracts the clamping function from separate welding or bolting operations and integrates it directly into the node element structure. The node's internal geometry (contact side and coupling side forming a hollow insertion channel) inherently provides the clamping action, removing the need for external clamping devices, gusset plates, or complex alignment tools that would increase manufacturing cost and labor time.
2Strength
If welding or bolting with gusset plates is used, then joint strength is improved, but assembly time and labor intensity increase
Solution Approach 1:
The invention merges the functions of the node element, clamping mechanism, and bar connection into a single integrated component. The node element's hollow insertion channel combines the bar passage function with the clamping function, allowing the bar to be inserted and clamped simultaneously in one operation. This eliminates the separate steps of positioning gusset plates, aligning bars, and performing welding or bolting operations, dramatically reducing assembly time and labor intensity.
Solution Approach 2:
The node element performs the clamping action automatically through its internal geometry when the bar is inserted. The contact side and coupling side of the node create a self-clamping mechanism that secures the bar without requiring external fasteners or complex assembly procedures. This self-securing feature enables rapid assembly while maintaining strong joint connections.
3Stability of the object's composition
If bar ends are modified with conical or flattened features for mating, then connection stability is improved, but bar strength is compromised
Solution Approach 1:
The invention applies the modification to the node element rather than the bar. The contact side and coupling side of the node element are specifically shaped to create the hollow insertion channel that provides clamping, while the bar remains uniform and unmodified throughout its length. This localizes the geometric complexity to the node element only, preserving the full strength of the bar while achieving stable connection through the node's internal clamping geometry.
4Strength
If thicker bars and node elements are used to compensate for connection weakness, then buckling resistance is improved, but material cost and weight increase
Solution Approach 1:
The node element's self-clamping mechanism creates effective clamped end conditions that maximize buckling resistance without requiring increased thickness. The automatic clamping action restrains both translational and rotational movements of the bar ends, achieving the theoretical maximum buckling resistance for clamped ends with standard bar and node dimensions. This eliminates the need to oversize components to compensate for weaker connection types.
Data Source
Figure 1a~1b
Figure 1c~2a
Figure 2b~3b
AI summary
Examples of first node elements (1), second node elements (1), and kits are disclosed. Also, methods for assembling a lattice structure are disclosed. The first node element (1) is provided. The first node element (1) comprises a coupling side (3), wherein the coupling side (3) further comprises one or more hollow insertion channels (4A, 4B), wherein each channel (4A, 4B) is configured to receive one of the elongated bars, and wherein each channel (4A, 4B) has a longitudinal axis, and the longitudinal axis of each channel (4A, 4B) is tilted at an angle with respect to a plane defined by the coupling side (3). Moreover, the first node element (1) comprises a contact side (2), wherein the contact side (2) comprises an opening (6), wherein the opening (6) is communicated with each of the hollow insertion channels (4A) forming a corresponding through-hole such that to form the lattice structure the elongated bars are inserted into the hollow channels (4A, 4B) from the contact side (2) to the coupling side (3) thereby traversing the corresponding through-hole.