Method for connecting flat, metallic workpieces and an application of said method
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Solution Overview
Problem
Current methods for connecting metal railing components, such as welding or using adhesives, are inefficient, require extensive technical effort, and result in increased production time and costs due to the need for corrosion protection and complex assembly processes.
Innovation Solution
A method utilizing a connecting element with a thread-tapping part and retaining mechanism for a plugged, pressed, and screwed non-detachable connection between two flat aluminum components, eliminating the need for weld seams and adhesives, and achieving immediate strength with reduced unit weight and invisible connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding or adhesive methods are used to connect metal railing components, then connection strength is achieved, but production time increases and corrosion protection requirements increase complexity
Solution Approach 1:
The connecting element is divided into distinct functional parts: a thread-forming part for creating threaded holes and a retention mechanism for securing the connection. This segmentation allows each part to perform its specific function efficiently without requiring additional steps for corrosion protection or adhesive curing, thus reducing production time while maintaining connection strength.
Solution Approach 2:
The thread-forming part of the connecting element automatically creates threaded holes in the aluminum components during the insertion process, eliminating the need for separate hole preparation steps. The retention mechanism simultaneously secures the connection, making the entire process self-contained and reducing overall production time without compromising connection strength.
2Strength
If welding or adhesive methods are used to connect metal railing components, then connection strength is achieved, but the complexity of corrosion protection and assembly processes increases
Solution Approach 1:
The thread-forming part and retention mechanism are combined into a single integrating element that performs both functions simultaneously during one insertion operation. This merging eliminates the need for separate welding or adhesive application processes and their associated corrosion protection requirements, thereby reducing assembly process complexity while ensuring strong connections.
Solution Approach 2:
The connecting element acts as an intermediary component that bridges two aluminum components through mechanical threading and retention, replacing the need for welding or adhesives. This intermediary approach simplifies the assembly process by providing a direct mechanical connection solution that does not require complex corrosion protection procedures.
3Strength
If steel components are used for railings, then strength and durability are achieved, but weight and corrosion protection requirements increase
Solution Approach 1:
The material parameter is changed from steel to aluminum, which has lower density and inherently better corrosion resistance. The connecting element is specifically designed to work with aluminum's material properties, creating threaded holes and securing connections that maintain structural strength despite the weight reduction. This parameter change achieves both weight reduction and improved corrosion resistance while preserving necessary strength.
4Ease of operation
If traditional connection methods are used for aluminum components, then assembly is simplified, but connection strength and reliability are compromised
Solution Approach 1:
The thread-forming part performs the preliminary action of creating threaded holes in the aluminum components during the insertion process itself, rather than requiring pre-drilled holes. The retention mechanism then immediately secures the connection, providing both ease of assembly and reliable, strong connections without compromising either aspect.
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
This method enhances productivity, standardization, and quality while reducing the need for costly anti-corrosion treatments, allowing for efficient and easy assembly of rustproof, prefabricated railings with improved visual appearance and reduced production time.
Implementation Method 1
a thread-forming part (4) for forming threaded holes in a first aluminium component (9) by means of a plugging, pressing and screwing process
Implementation Method 2
a retention mechanism (7) for preventing a detaching of the connecting element (1)
Data Source
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AI summary
Aluminum is also used instead of steel or CNS in the manufacture of products for the construction sector - especially railings. This opens up new possibilities for producing lighter and rustproof constructions compared to pure steel constructions. A method based on a new type of connecting element is described, which enables the production of adhesive-free and non-detachable connections between two flat aluminum components, whereby the overall effort for production is reduced and the assembly of the prefabricated elements on site is easier due to the lower unit weight can. Overall, the productivity for manufacturing such products, the quality and the visual appearance of such products can be improved.