Trailer Coupling Support Assembly with Plug-in and Bonded Connections
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Solution Overview
Problem
Existing carrier arrangements for trailer hitches and load carriers face mechanical stress due to heavily loaded welded connections, necessitating an improved connection method that combines form-fitting and material bonding for enhanced stability and durability.
Innovation Solution
A plug-in projection engages with a plug-in receptacle, with additional material bonding through methods like gluing, welding, or soldering, creating a dual connection mechanism that distributes loads effectively and provides additional security.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welded connections are used to connect components of a carrier arrangement, then the connection provides high strength, but the mechanical stress becomes heavily loaded and the reliability decreases
Solution Approach 1:
The connection is segmented into two distinct parts: a form-fitting connection component (plug-in projection and receptacle) and a material bonding component (welding, gluing, or soldering). This segmentation allows each component to fulfill a specific function - the form-fitting part provides precise positioning and load distribution, while the material bonding part ensures strong attachment - thereby reducing the mechanical stress concentration that occurs in traditional single-method welded connections and improving overall reliability
Solution Approach 2:
The connection methodology combines two different connection mechanisms (form-fitting mechanical connection and material bonding) into a composite connection system. This composite approach leverages the advantages of both methods: the form-fitting connection provides geometric stability and load distribution, while the material bonding provides strong attachment, creating a more reliable and stress-resilient connection than either method alone
2Stability of the object's composition
If additional material bonding is added to the plug-in connection, then the structural integrity is enhanced, but the device complexity increases
Solution Approach 1:
The form-fitting connection and material bonding are merged into a single integrated connection process. The plug-in projection with integrated bonding elements (such as welding protrusions or adhesive application surfaces) combines both connection functions in one structural feature, eliminating the need for separate connection components and reducing overall device complexity while maintaining enhanced structural integrity
3Stress or pressure
If a dual connection method is used, then the load distribution is improved and stress is reduced, but the manufacturing complexity increases
Solution Approach 1:
The form-fitting connection is established first through the plug-in operation, which pre-positions the components and distributes the initial load. The material bonding is then applied as a preliminary preparatory step before final assembly, ensuring that the bonding material is properly positioned and the components are already aligned, thereby simplifying the manufacturing process despite the dual connection method
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
The dual connection method enhances the structural integrity and stability of the carrier arrangement, reducing mechanical stress and allowing for a cost-effective, space-efficient design while maintaining high tensile strength.
Implementation Method 1
a form-fitting connection is created between the components of the carrier arrangement that are to be connected to one another, in that the plug-in projection engages in the plug-in receptacle
Implementation Method 2
the plug-in projection is additionally glued, welded or the like. A soldered connection, in particular a hard-soldered connection, is also readily advantageous
Implementation Method 3
A soldered connection, in particular a hard-soldered connection, is also readily advantageous
Data Source
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AI summary
The invention relates to a support arrangement for a trailer coupling (90) or a load carrier, comprising a cross member and at least one bracket (11, 13) arranged on the cross member (20) for a trailer coupling (90) or for a coupling part of a load carrier, and optionally side carriers (30, 31) connected to the cross member (20) for mounting on the rear of a vehicle body. The support arrangement is designed in such a way that at least two of the components of the support arrangement (10) and/or at least two of its component parts are connected to each other by a plug connection, wherein a plug projection (50, 51, 60, 61) projecting in front of one component or component engages in a plug receptacle (33-36) of the other component or component, and the at least one plug projection is connected to the other component or component by means of a material-fit connection.