Split Carbon Rod End Terminal Attachment for Stable Tensile Joints
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Solution Overview
Problem
Existing methods for attaching end terminals to stranded steel cables and carbon rods fail to provide a stable connection for pultruded solid carbon rods due to mechanical interlocking, and existing solutions for carbon rods require multiple parallel strands, limiting their application.
Innovation Solution
A method involving splitting a pultruded solid carbon rod along its longitudinal axis into smaller segments, inserting these segments into an end terminal, and filling the space with a solidifiable liquid-phase material to create a form-fitting connection, using a splitting device with a centering clamp and movable blades to achieve precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple parallel strands are used for end terminal attachment, then stable connection is achieved, but the method cannot be applied to solid carbon rods and requires complex strand separation and bending processes
Solution Approach 1:
The solid carbon rod is segmented by splitting it into multiple smaller rod portions along its longitudinal axis. This segmentation transforms the solid rod into a configuration similar to stranded cables, enabling the end terminal attachment method to be applied to solid carbon rods while avoiding the complexity of strand separation and bending processes.
2Reliability
If mechanical interlocking is used for strand connection, then form-fitting connection is achieved, but the connection is unstable for solid carbon rods
Solution Approach 1:
A liquid-phase material is introduced as an intermediary substance between the split carbon rod portions and the end terminal. This material fills the spaces and forms a bonding layer that solidifies to create a stable connection, replacing the inadequate mechanical interlocking method and enabling reliable attachment while maintaining process simplicity.
3Strength
If conventional end terminal attachment methods are used, then manufacturing process is simple, but tensile strength and manufacturing flexibility are limited
Solution Approach 1:
The carbon rod is pre-split into multiple portions before end terminal attachment. This preliminary action creates a configuration that enhances tensile strength and manufacturing flexibility while allowing for faster attachment processes, as the split structure enables more efficient material distribution and bonding.
4Quantity of substance
If solid carbon rod is used, then high carbon fiber content is achieved, but cross-sectional area is larger compared to stranded structures
Solution Approach 1:
By segmenting the solid carbon rod into multiple smaller portions and arranging them within the end terminal, the configuration achieves high carbon fiber content similar to solid rods while reducing the overall cross-sectional area through more efficient space utilization, comparable to stranded structures.
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
Enables a faster, more practical, and stable attachment of end terminals to pultruded solid carbon rods, enhancing tensile strength and manufacturing flexibility while reducing the cross-sectional area, and allowing for higher carbon fiber content.
Implementation Method 1
introducing a solidifiable liquid-phase material into the end terminal in an amount sufficient to fill available space within the end terminal
Data Source
AI summary
An end terminal is attached to a pultruded solid carbon rod by first splitting an end portion of the pultruded solid carbon rod into plural, relatively smaller carbon rod portions which are then fitted into the end terminal and fixed in place by a solidifiable liquid-phase material.