Toggle Fastener Beam for Thin-Walled Load Distribution
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Solution Overview
Problem
Existing toggle bolts fail to effectively distribute loads on thin-walled components, leading to stress peaks and potential failure, especially when subjected to high forces or deflection.
Innovation Solution
A toggle bolt design featuring a bar composed of two distinct components: a stiff supporting body and an elastic contact body, with the supporting body extending over at least half the length and the contact body providing surface contact, allowing for better load distribution and stress management through geometric and material alignment, and featuring a pivot connection for improved assembly and load transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-material beam is used, then the structure is simple and easy to manufacture, but the load distribution is poor and stress peaks occur on thin-walled components
Solution Approach 1:
The beam is constructed as a composite structure with a supporting body made of rigid material (metal or glass fiber reinforced plastic with ≥15% fiber content) and a contact body made of softer material, allowing optimal load distribution while maintaining structural integrity
Solution Approach 2:
Different regions of the beam have different material properties: the supporting body uses rigid material for structural strength and load distribution, while the contact body uses softer material to prevent stress peaks on the thin-walled component surface
2Strength
If a very rigid beam is used, then the load transfer within the beam is efficient, but point loads occur on the thin-walled component causing cutting and failure
Solution Approach 1:
The contact body is made of softer material than the supporting body, creating a local compliance zone that distributes point loads over a larger area of the thin-walled component while the rigid supporting body maintains overall structural strength
Solution Approach 2:
The composite structure combines rigid supporting body material for efficient load transfer with softer contact body material that acts as a stress-distributing interface, preventing the rigid beam from directly transmitting point loads to the thin-walled component
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
Enhances the load-bearing capacity of toggle bolts by distributing forces over a larger area, reducing the risk of failure in thin-walled components and preventing point loads, while allowing for flexible adaptation to different materials and assembly conditions.
Implementation Method 1
the contact body can be aligned in terms of shape and material in such a way that the effective forces are distributed as well as possible while avoiding stress peaks
Implementation Method 2
the beam can be adapted in terms of load transfer from a screw screwed into the beam to the respective thin-walled component
Implementation Method 3
areas that are to be particularly stiff to distribute the load within the beam can be formed by a first component with a favorable combination of cross section and choice of material, while areas that are used for direct transmission to the thin-walled component are particularly elastic
Data Source
Figure 1~2
Figure 3~5
Figure 6
AI summary
The invention relates to a toggle anchor (1) for fastening an object to a thin-walled component (24) with a beam (2) having an opening (5) for receiving a screw, and with a band (3) connected to the beam (2) and serving to hold and position the beam (2) during assembly. To increase the load-bearing capacity of such an anchor, the invention proposes that the beam (2) consist of at least two components.