Threaded Rod Connector Using Rough Wedge Surfaces for Multi-Size Grip
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Solution Overview
Problem
Existing threaded rod connectors require precise alignment and mating threads, limiting their versatility and manufacturing efficiency, as they struggle to securely engage different threaded rod sizes and diameters.
Innovation Solution
The threaded rod connector features threadless rod contact surfaces with a surface roughness of 7.0 μm or greater and a cage that aligns and secures rod engagement wedge segments, allowing frictional engagement of various rod diameters without geometric constraints, and a tapered surface for wedging, facilitating secure engagement of both metric and imperial sized rods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mating threads are provided on rod contact surfaces for secure engagement, then engagement reliability is improved, but manufacturing precision requirements increase and versatility decreases
Solution Approach 1:
The patent replaces the mechanical thread engagement system with a friction-based engagement system. The rod contact surfaces are made significantly rougher (Ra ≥ 7.0 μm) to create high friction that secures the threaded rod without requiring precise thread mating. This substitution eliminates the need for precise alignment while maintaining engagement reliability through friction rather than geometric interlocking.
Solution Approach 2:
The patent changes the surface roughness parameter of the rod contact surfaces to Ra ≥ 7.0 μm, which is significantly rougher than conventional surfaces. This parameter change enables the surface to generate sufficient friction for secure engagement, allowing the connector to work with various thread types and diameters without requiring precise thread matching, thus improving both reliability and versatility while reducing manufacturing precision requirements.
2Reliability
If mating threads are provided on rod contact surfaces, then engagement security is improved, but versatility to engage different rod sizes decreases
Solution Approach 1:
The patent makes the rod engagement wedge segments universal by providing threadless contact surfaces with high roughness. This single design can securely engage threaded rods of different sizes, diameters, and thread types (metric and imperial) without requiring different connectors or thread configurations. The friction-based engagement mechanism adapts to various rod dimensions, making the connector multi-functional and highly versatile.
Solution Approach 2:
By changing the surface roughness parameter to Ra ≥ 7.0 μm and eliminating threads, the contact surfaces become adaptable to different rod sizes and thread types. The high friction coefficient compensates for the lack of geometric constraints, allowing secure engagement across a wide range of rod dimensions and thread specifications, thereby achieving universality.
3Manufacturing precision
If precise alignment of rod engagement wedge segments is required, then engagement accuracy is improved, but manufacturing effort increases
Solution Approach 1:
The patent replaces the precision mechanical thread-mating system with a friction-based system. The high surface roughness (Ra ≥ 7.0 μm) creates sufficient friction to secure the rod without requiring precise alignment of the wedge segments. This substitution dramatically reduces manufacturing complexity and effort while maintaining secure engagement, as the friction mechanism is tolerant of alignment variations.
4Reliability
If thread structures are provided on rod contact surfaces, then engagement reliability is improved, but device complexity increases
Solution Approach 1:
The patent extracts and removes the thread structures from the rod contact surfaces, retaining only the essential function of securing the rod. By eliminating the complex thread geometries and replacing them with simple rough surfaces, the device complexity is significantly reduced while engagement reliability is maintained through friction. This simplification makes the connector easier to manufacture and more versatile.
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 solution enhances the connector's versatility and manufacturing ease by reducing alignment precision requirements and enabling secure engagement of diverse rod sizes, while the cage and tapered surface ensure reliable operation with reduced manufacturing effort.
Implementation Method 1
the housing has a tapered surface, which delimits the cavity, and which tapers towards the mouth for wedging the rod engagement wedge segments against the threaded rod
Implementation Method 2
at least one of the rod contact surfaces is threadless and has a surface roughness Ra of 7.0 μm or greater... the engagement of the threaded rod by the rod engagement wedge segments is primarily frictional
Data Source
AI summary
A threaded rod connector includes a housing having a cavity for receiving a threaded rod therein where the housing has a mouth for inserting the threaded rod into the cavity. A plurality of rod engagement wedge segments are disposed within the cavity where each of the plurality of rod engagement wedge segments has a rod contact surface for engaging the threaded rod. The housing has a tapered surface which delimits the cavity and which tapers towards the mouth for wedging the plurality of rod engagement wedge segments against the threaded rod. At least one of the rod contact surfaces is threadless and has a surface roughness of 7.0 μm or greater.