Twisted-Loop Lattice Nodes Without Welding or Fasteners
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Solution Overview
Problem
Existing lattice structures with nodal points require welding or additional materials, leading to high production costs, complexity, and potential corrosion issues, while also compromising structural integrity under high loads.
Innovation Solution
A lattice structure with nodes formed by twisted loops of longitudinal and transverse elements, eliminating the need for external connection means and ensuring a non-displaceable, shear-resistant connection, using high-strength steel for enhanced durability and corrosion protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welded joints or mechanical connecting elements are used to connect longitudinal and transverse elements at nodes, then the structural integrity and shear strength are improved, but the manufacturing complexity and production costs increase significantly
Solution Approach 1:
The patent merges the longitudinal and transverse elements by interlocking them through loops formed on the elements themselves, eliminating the need for separate connecting elements. The loops of longitudinal elements and transverse elements are interlocked and twisted together to form integrated nodes, combining the function of connection and structural element into a single unified system.
Solution Approach 2:
The longitudinal and transverse elements create their own connection mechanism through loops that are formed directly on the elements. These loops interlock and twist together to form self-contained nodes that do not require external fasteners, welding, or additional connecting materials. The structure serves its own connection needs through the inherent geometry of the elements.
2Reliability
If welded joints are used to connect the chord rods, then the structural integrity is improved, but the labor and cost expenditure increase significantly
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical interlocking system using twisted loops. Instead of using heat and pressure to fuse materials, the connection is achieved through the geometric interlocking and twisting of loops, which creates a mechanically strong bond without the complexity and cost of welding operations.
Solution Approach 2:
The patent uses simple loop structures that can be formed through relatively simple processes compared to welding. The loops are created by bending and twisting the elements themselves, requiring minimal additional materials or complex equipment, thereby reducing both labor and material costs while maintaining structural integrity.
3Strength
If additional wire material or connecting elements are used at nodes, then the connection strength is improved, but the manufacturing effort and production costs increase
Solution Approach 1:
The loops formed on the longitudinal and transverse elements serve multiple functions: they provide the connection mechanism, create the node structure, and enable the twisting action that secures the joint. The same element that provides structural support also provides the connection feature, eliminating the need for separate connecting materials and simplifying the manufacturing process.
4Reliability
If welded joints are used at nodes, then the structural integrity is improved, but the corrosion protection is compromised due to structural changes and potential corrosion at weld points
Solution Approach 1:
The patent extracts the welding process and all associated thermal zones from the construction method. By using mechanical interlocking of loops instead of welding, the harmful thermal effects that create microstructural changes and corrosion-prone zones are completely eliminated. The connection is formed through cold-forming and mechanical interlocking, avoiding all corrosion-inducing processes.
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 solution provides a cost-effective, durable, and corrosion-resistant lattice structure with improved stability under load, reducing production complexity and maintaining structural integrity without weakening welds, allowing for efficient and economic production.
Implementation Method 1
the longitudinal and transverse elements are twisted with themselves... This creates a non-displaceable connection between the longitudinal and transverse elements
Implementation Method 2
the longitudinal and transverse elements are twisted with themselves at the intersections of the wires and twisted with themselves
Implementation Method 3
the longitudinal and/or transverse elements are at least partially made of high-strength steel with a strength of 700 N/mm2 to 2800 N/mm2... the shear strength of the nodes ensures that the grid experiences only minimal deformation even under high loads
Data Source
Figure 1~3b
Figure 4~7
Figure 8~9
AI summary
The invention relates to a lattice structure consisting of intersecting longitudinal and transverse elements (2 and 3) such as wires, stranded wires, ropes, rods and/or profiled sections, having intersection points (6) associated therewith. These longitudinal and transverse elements (2 and 3) are interconnected by twisting at least at said intersection points (6). The connection may also be established by insertion one into another and/or by knotting. This results in a connection between the longitudinal and transverse elements which can be established without external connector means and with comparatively low overheads.