Sleeper Connector Flexible Core Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for connecting hollow chamber profiles to sleepers with uneven surfaces require complex constructions or precise positioning of filling cores, leading to assembly complications and potential sealing issues.
Innovation Solution
A multi-part sleeper connector system where the sleeper holder and filling core are connected in a flexible but spaced manner, allowing for easy assembly and ensuring a tight seal through elastic elements and seals, with the filling core being inserted into the hollow chamber profile and secured with screws to compress the seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the filler core is precisely positioned and screwed to the hollow chamber profile before assembly, then the connection tightness is improved, but the assembly complexity increases
Solution Approach 1:
The filler core is designed with elastic elements that allow it to be flexible during assembly but become rigid when compressed between the hollow chamber profile and sleeper holder, automatically achieving tight connection without complex positioning procedures
Solution Approach 2:
The elastic filler core self-adjusts during assembly to compensate for tolerances and positioning variations, automatically ensuring connection tightness without requiring precise manual positioning or additional fastening steps
2Reliability
If permanently elastic seals are compressed to achieve sealing effect, then the sealing function is improved, but the clamping force requirement increases
Solution Approach 1:
The seal compression is achieved not by increasing overall clamping force but by locally compressing the elastic seal between the hollow chamber profile end face and the sleeper holder top surface through the filler core's elastic deformation
Solution Approach 2:
The combination of the rigid hollow chamber profile, elastic filler core, and flexible seal creates a composite connection system where each material contributes its properties to achieve sealing without excessive clamping force
3Reliability
If the hollow chamber profile end face is milled to match the threshold surface contour, then the sealing contact is improved, but the manufacturing complexity increases
Solution Approach 1:
The sealing function is extracted from the hollow chamber profile itself and transferred to a separate elastic seal element and filler core, allowing the profile to remain simple while achieving reliable sealing through the elastic components
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
Simplifies the assembly process while ensuring a secure and sealed connection between the hollow chamber profile and the sleeper, accommodating varying tolerances and providing a reliable sealing function.
Implementation Method 1
Permanently elastic seals are often used for this purpose; to achieve the desired sealing effect, these seals must be compressed by at least a few tenths of a millimeter during the installation of the sleeper connector
Data Source
Figure 1
Figure 2~6
Figure 7~8
AI summary
The invention relates to a sleeper connector (10) for connecting a hollow chamber profile (20) having at least one hollow chamber (22) to the top surface (31) of a sleeper (1). The sleeper connector (10) comprises at least one sleeper holder (11) and a filler core (12) that can be inserted into the hollow chamber (22), wherein the sleeper holder (11) has a seal (16) on its top surface (14) facing the filler core (12). To facilitate assembly, the filler core (12) and/or the sleeper holder (11) have means that provide a flexible, spaced-apart attachment of the filler core (12) to the sleeper holder (11). For assembly, the filler core (12) is first flexibly spaced from the sleeper holder (11), and the sleeper holder (11) is then firmly connected to the top surface (31) of the sleeper (1). The hollow chamber profile (20) is then placed on the sleeper connector (10) or the filling core (12) is inserted into the hollow chamber (22).The filling core (12) is then firmly connected to the hollow chamber profile (20), in particular by means of a screw connection (30). By means of at least one screw (8), which is screwed from the underside of the sleeper (1) through the sleeper holder (11) into the filling core (12), the hollow chamber profile (20) is pressed onto the top surface (14) of the sleeper holder (11) and/or the seal (16) arranged between the hollow chamber profile (20) and the top surface (14) of the sleeper holder (11), whereby the distance between the filling core (12) and the sleeper holder (11) is reduced by compressing the seal (16).