Rolled Zinc Thread Flanks for Corrosion-Resistant Load Members
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Solution Overview
Problem
Existing methods for producing tension or compression members with corrosion-protected threads are inefficient, environmentally harmful, and provide inadequate corrosion protection and dynamic load resistance due to reworking and heat-induced damage to the zinc layer, which compromises the strength and longevity of the thread.
Innovation Solution
A statically permanently loadable tension or compression member with thread flanks featuring a rolled zinc surface, achieved through cold forming without cutting, ensuring a continuous fibre flow and complete zinc coverage for enhanced corrosion protection and fatigue resistance, and a streamlined production process that eliminates the need for reworking and toxic fume extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thread is galvanised after production, then corrosion protection is applied to the thread, but the zinc layer must be removed again during reworking to restore smooth thread running
Solution Approach 1:
The zinc layer is applied to the round material before thread formation through cold rolling. This preliminary application of corrosion protection allows the thread to be formed cold without requiring subsequent removal of the zinc layer, eliminating the need for reworking while maintaining both corrosion protection and smooth thread running
Solution Approach 2:
Instead of the conventional sequence of forming the thread first and then applying corrosion protection (which requires later removal), the invention inverts the sequence by applying the zinc layer first and then forming the thread cold. This reversal eliminates the contradiction between corrosion protection and ease of manufacture
2Ease of manufacture
If the thread is cut to form the thread flanks, then the thread can be formed, but the continuous fibre flow is interrupted reducing dynamic load resistance
Solution Approach 1:
The invention replaces the cutting process with cold rolling to form the thread flanks. This mechanical substitution maintains continuous fibre flow through the material while still achieving proper thread formation, thereby preserving dynamic load resistance without compromising manufacturability
3Ease of operation
If reworking processes such as thread cleaning are performed, then the thread runs smoothly, but toxic vapours are generated requiring additional extraction equipment
Solution Approach 1:
The invention extracts or removes the reworking step from the manufacturing process entirely. By applying the zinc layer before thread formation and using cold rolling, the process eliminates the need for subsequent thread cleaning operations that generate toxic vapours, while still achieving smooth thread running through the cold-formed zinc surface
4Ease of manufacture
If the zinc layer is heated during thread cleaning, then the thread can be reworked, but environmentally harmful vapours are generated
Solution Approach 1:
The zinc layer is applied in advance before thread formation, eliminating the need for later heating and reworking operations. This preliminary action prevents the generation of environmentally harmful vapours while still providing the necessary corrosion protection and smooth thread surface
Solution Approach 2:
The invention converts the potential harm of heating zinc (which generates harmful vapours) into a benefit by performing all thread formation operations cold. The cold rolling process achieves smooth thread running without heating, thereby eliminating harmful emissions while maintaining manufacturing effectiveness
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 method provides improved corrosion protection and increased resistance to dynamic loads, maintaining the strength benefits of cold forming while ensuring efficient and environmentally friendly production by maintaining the zinc layer integrity and avoiding heat-induced damage.
Implementation Method 1
galvanising the material of the member before the thread is incorporated
Implementation Method 2
During thread cleaning, the zinc layer in the region of the thread is heated, which generates the toxic and environmentally harmful vapours
Implementation Method 3
achieved through cold forming without cutting, ensuring a continuous fibre flow
Data Source
AI summary
The present application relates to a statically permanently loadable tension member or compression member (10) for a structure, which member comprises, on both end portions (12), thread flanks (14) of a thread for receiving a connection component. According to the invention, the thread flanks (14) are provided at least partially with a rolled zinc surface (16).