Thin Friction Connector Assembly for Flush Pre-Mounted Fastening
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Solution Overview
Problem
Existing friction-increasing connecting elements with thicknesses of 0.8 mm or less face challenges in mechanical pre-assembly due to the inability of countersunk screws to sink properly, leading to incomplete contact and impaired torque transmission in applications like wind turbines and hydropower stations.
Innovation Solution
A connecting system featuring a metal substrate with hard particles and a metallic binder layer, incorporating openings with extensions that allow for pre-assembly by bending down the extensions to secure the fastening elements, ensuring the head of the fastening element does not protrude and facilitating secure attachment to a component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If countersunk screws are used for pre-assembly of thin connecting elements (0.8 mm or less), then the connecting element can be mechanically fixed to a component, but the screw head cannot sink into the connecting element and would protrude, preventing proper function and torque transmission
Solution Approach 1:
The opening is segmented into two functional zones: an inner hole for inserting the fastening element shaft and extensions at the outer contour for securing the fastening element head. This segmentation allows the fastening element to be mechanically fixed without the head protruding, resolving the contradiction between ease of pre-assembly and reliability of contact.
Solution Approach 2:
The opening structure transitions from a simple hole to a three-dimensional feature with extensions directed toward the inner hole. These extensions create additional spatial constraints that prevent screw head protrusion while maintaining easy insertion, effectively adding a dimensional solution to a two-dimensional problem.
2Weight of moving object
If the connecting element thickness is reduced to 0.8 mm or less, then the weight is reduced and no design changes are needed for the components, but conventional countersunk screws cannot be used for pre-assembly
Solution Approach 1:
The opening is divided into an inner hole region and extension regions at the outer contour. This segmentation enables the fastening element to be secured without requiring the screw head to sink into the thin connecting element, making pre-assembly feasible for elements with thickness of 0.8 mm or less while maintaining light weight.
Solution Approach 2:
The extensions act as an intermediary structure between the inner hole and the outer surface of the connecting element. They provide a mechanical interface that secures the fastening element head without requiring the head to protrude or sink into the thin element, enabling pre-assembly of ultra-thin connecting elements.
3Ease of operation
If the opening inner hole diameter is made larger to facilitate fastening element insertion, then the shaft can be easily inserted, but the fastening element head may protrude from the connecting element
Solution Approach 1:
The opening is segmented into an inner hole with sufficient diameter for easy shaft insertion and extensions at the outer contour that constrain the fastening element head. This segmentation allows the inner hole to be large enough for easy insertion while the extensions prevent head protrusion, resolving the contradiction between ease of operation and reliability.
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 reliable pre-assembly and secure attachment of the connecting element to a component, preventing separation during mounting and allowing for efficient torque transmission, with the option to reuse and reattach the connecting element, enhancing assembly efficiency and reliability.
Implementation Method 1
the joining surfaces are provided with hard particles, which are fixed on the metal substrate by means of a metallic binder layer
Implementation Method 2
bending down the at least one extension of the at least one opening by fastening the fastening element
Implementation Method 3
the particles consist of a hard material... By using this separate connecting element, the coefficient of static friction can be increased in frictional connections
Data Source
Figure 1
Figure 2A~2D
Figure 3A~3K
AI summary
The present disclosure relates to a connecting element and to a process for producing said connecting element. The present disclosure further relates to a connecting system and a device comprising said connecting element, and to a process for fixing said connecting element to a first component. The present disclosure further relates to the use of said connecting element and connecting system for friction-increasing connection of a first and a second component in energy generation, specifically in wind turbines and hydropower turbines, and in machine, plant, motor vehicle and aircraft construction.