Modular Scaffold Connector Resolving Misalignment and Twist
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Solution Overview
Problem
Current modular scaffolding end connectors suffer from misalignment issues due to metal deformation, resulting in a twisted design that affects proper engagement with vertical members, and do not provide a secure positive lock against twisting forces, leading to safety concerns and gaps in the working surface.
Innovation Solution
A new end connector design with separately formed sidewalls and a locking latch mechanism featuring a rotating upper latch and lower lock member that interfere when locked, ensuring proper alignment and a secure engagement with vertical scaffold members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the end connector is formed by bending and stretching metal to create a cylindrical top portion, then the connector can be manufactured in a single piece, but the metal deformation causes misalignment and twisting of the connector sides
Solution Approach 1:
The connector is divided into two separate components: a cylindrical housing and a lid. The housing is formed by bending and stretching metal into a cylindrical shape with open top, while the lid is a separate piece that closes the top. This segmentation prevents the misalignment and twisting issues that occur when trying to form a complete cylindrical top in a single piece, as each component can be manufactured independently with proper alignment features.
2Ease of operation
If a pivoting latch member is used to engage with ring members, then the connector allows for hand actuation and ease of assembly, but the joint retains play and lacks a secure positive lock
Solution Approach 1:
The latch member is designed to pivot between two distinct positions: an engaged position where it secures the ring member between itself and the hook engagement section, and a disengaged position where it allows assembly and disassembly. This dynamic positioning provides both ease of operation through hand actuation and reliability through a secure locked position that eliminates play in the joint.
3Ease of operation
If the connector housing is open at the top to allow latch operation, then the latch can be actuated, but debris can fall into the interior and damage pivot pins and springs
Solution Approach 1:
The lid is designed to be placed on the housing before the latch operation begins, creating a protective enclosure. This preliminary action of closing the top opening prevents debris from falling into the interior and damaging sensitive components like pivot pins and springs, while still allowing the latch to be actuated through the designed access points or openings in the lid.
4Device complexity
If the end connector is wider than the horizontal pipe, then the connector can house the latching mechanism, but scaffold boards cannot be placed over the connector creating gaps in the working surface
Solution Approach 1:
The connector housing is designed to fit within the confines of the horizontal pipe, with the lid closing the top opening. This nested configuration allows the latching mechanism to be housed within the connector while maintaining a compact overall dimension that does not protrude beyond the pipe width, enabling scaffold boards to be placed directly over the connector without creating gaps in the working surface.
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 new design eliminates misalignment issues, provides a secure positive lock against both upward and twisting forces, and allows scaffold boards to be positioned closer to the edge of the connector, enhancing safety and functionality.
Implementation Method 1
The latch member can be spring loaded to bias the latch into a locking or actuated position.
Implementation Method 2
the connector includes a wedge that is driven (generally by a hammer) into position below the upper ring member, thereby wedging the ring against the end connector hood section
Data Source
AI summary
The invention is an end connector for a horizontal scaffold member where the top of the end connector is inserted into the interior of a scaffold pipe. The invention includes a locking latch that includes a rotating latch member and a rotating lock that interfere when the latch is locked.