Joined Two-Diameter Fastener Shaft for Hollow-Base Anchoring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing fastening systems for spaced assembly are complex to produce and often require dowels, which can be too short for fastening in substructures with hollow chambers, leading to inefficiencies and quality issues.
Innovation Solution
A fastening element with a shank comprising two sections of different diameters, where the threaded section and another section are formed separately and joined at a material interface, allowing for easy assembly and adaptation to various anchoring bases with or without dowels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional dowels are used for fastening in substructures with hollow chambers, then the fastening system is simple to assemble, but the dowel length is insufficient to achieve reliable fastening in hollow substrates
Solution Approach 1:
The fastening element is divided into multiple sections along its longitudinal axis, including a head section, a shaft section with first diameter, and a tip section with second diameter. This segmentation allows each section to serve specific functions: the shaft section provides structural support while the larger-diameter tip section ensures reliable anchoring in hollow substrates by spanning across hollow chambers.
Solution Approach 2:
Different sections of the fastening element have different local properties, specifically different diameters. The tip section has a larger diameter than the shaft section, creating local quality variations that enable the tip to effectively bridge hollow chambers and achieve reliable fastening in substrates with hollow spaces.
2Stability of the object's composition
If a one-piece fastening element with varying diameter sections is produced, then the structural integrity is improved, but the manufacturing complexity increases significantly
Solution Approach 1:
The fastening element is manufactured as separate sections (head section, shaft section, tip section) that are subsequently connected. This segmentation approach maintains structural integrity through proper connection methods while significantly reducing manufacturing complexity compared to producing a single varying-diameter component in one operation.
Solution Approach 2:
Separately manufactured sections are merged together to form the complete fastening element. The connection between sections can be achieved through threading, interference fitting, or other joining methods, combining the advantages of simplified individual section manufacturing with the structural integrity of a unified component.
3Adaptability or versatility
If the fastening element has sections with different diameters, then the adaptability to various anchoring bases is improved, but the manufacturing precision requirements increase
Solution Approach 1:
By manufacturing different diameter sections separately, each section can be produced within its own tolerance range, which is more achievable than maintaining tight tolerances across a continuously varying diameter. The connection interface between sections serves as a reference point that ensures proper alignment and functional precision.
Solution Approach 2:
Different sections have different local diameter specifications optimized for their specific functions. The larger tip section diameter is optimized for anchoring in hollow substrates, while the smaller shaft section diameter is optimized for passing through insulation layers and mounting elements, with each section manufactured to its specific dimensional requirements.
4Productivity
If separate sections are joined to form the fastening element, then the production effort is reduced, but the connection strength at the material interface may be compromised
Solution Approach 1:
The fastening element is produced as separate sections that are subsequently connected, significantly reducing production effort compared to manufacturing a single complex varying-diameter component. The connection between sections is designed to maintain sufficient strength for the intended application through appropriate joining methods such as threading or interference fitting.
Data Source
Figure 1~4
Figure 5~6
Figure 6A
AI summary
Method for manufacturing a fastening element (100), wherein in the method a drive (106) for driving the fastening element (100) is formed and a shaft (108) is formed, by separately forming a threaded section (110) which is provided at least partially with a first shaft diameter (d) with a thread (122) arranged thereon, separately forming another section (112) which is provided at least partially with a second shaft diameter (D) which is larger than the first shaft diameter (d), wherein one of the threaded section (110) and the other section (112) is provided with a projection (161); and subsequently joining the threaded section (110) to the other section (112) at a material interface (177).