Connecting system for tensile elements

• US 20040155518A1
• Filed: 01/12/2004
• Published: 08/12/2004
• Est. Priority Date: 01/13/2003
• Status: Active Grant

• Current Assignee: Raphael Schlanger
• Original Assignee: Raphael Schlanger
• Inventors: Schlanger, Raphael
• Granted Patent: US 7,357,460 B2
• Time in Patent Office: Days
• US Class Current: 301/58
• CPC Class Codes: B60B 1/0261 characterised by spoke form
• CPC Class Codes: B60B 1/0269 the spoke being curved or deformed over substantial part of length
• CPC Class Codes: B60B 1/041 of bicycle wheels bicycle rims characterised by means for attaching spokes B60B21/062
• CPC Class Codes: B60B 1/044 by the use of spoke nipples
• CPC Class Codes: B60B 21/025 the transverse section being hollow
• CPC Class Codes: B60B 21/062 for bicycles
• CPC Class Codes: B60B 21/064 characterised by shape of spoke mounting holes, e.g. elliptical or triangular
• CPC Class Codes: B60B 5/02 made of synthetic material
• CPC Class Codes: Y10T 403/47 Molded joint
• CPC Class Codes: Y10T 403/472 including mechanical interlock
• CPC Class Codes: Y10T 403/473 Socket or open cup for bonding material

Abstract

An improved connecting system for tensile elements, including a longitudinal tensile element having an end portion and a cross-section thereof, a deformable connecting element; a bracing element, and a tensile axis of applied tensile load along said longitudinal tensile element. The deformable connecting element surrounds the cross section of the longitudinal tensile element and the deformable connecting element is joined to the longitudinal tensile element by means of plastic deformation of said deformable connecting element. The deformable connecting element is connected to the bracing element.

Claims

1. A tensile connector assembly comprising:

a longitudinal tensile element having an end portion and a cross-section thereof;

a deformable connecting element;

a bracing element;

a tensile axis of applied tensile load along said longitudinal tensile element;

wherein said deformable connecting element surrounds the cross section of said longitudinal tensile element;

wherein said deformable connecting element is joined to said longitudinal tensile element by means of plastic deformation of said deformable connecting element; and

wherein said deformable connecting element is connected to said bracing element.

2. A tensile connector assembly according to claim 1, including a second tensile element joined to said longitudinal tensile element, wherein said deformable connecting element serves as a coupling element to join said second tensile element to said longitudinal tensile element and wherein said deformable coupling element surrounds the cross-section of both said longitudinal tensile element and said second tensile element.

3. A tensile connector assembly according to claim 2, wherein said longitudinal tensile element includes non-circular cross-section geometry to mate with corresponding geometry of said second tensile element to prevent rotation of said longitudinal tensile element with respect to said second tensile element.

4. A tensile connector assembly according to claim 2, wherein said deformable connecting element includes reinforcement fibers in a matrix and wherein said reinforcement fibers span across the joint between said longitudinal tensile element and said second tensile element along said tensile axis.

5. A tensile connector assembly according to claim 2, wherein said deformable connecting element contacts both said longitudinal tensile element and said second tensile element.

6. A tensile connector assembly according to claim 5, including an overlap region, wherein said longitudinal tensile element overlaps said second tensile element along said tensile axis at said overlap region and wherein said overlap region contacts said deformable connecting element.

7. A tensile connector assembly according to claim 6, wherein a portion of said deformable connecting element extends in between said longitudinal tensile element and said second tensile element in said overlap region.

8. A tensile connector assembly according to claim 6, wherein said longitudinal tensile element and said second tensile element contact each other in said overlap region.

9. A tensile connector assembly according to claim 8, wherein said longitudinal tensile element is interlocked and engaged to said second tensile element in said overlap region.

10. A tensile connector assembly according to claim 6, wherein said longitudinal tensile element includes an open cup geometry with a longitudinal opening and wherein said open cup geometry partially surrounds the cross section of said second tensile element to overlap said second tensile element in said overlap region.

11. A tensile connector assembly according to claim 6, wherein said longitudinal tensile element includes a closed cup geometry and wherein said closed cup geometry surrounds the cross section of said second tensile element to overlap said second tensile element in said overlap region.

12. A tensile connector assembly according to claim 6, wherein said longitudinal tensile element includes a forked end and wherein said forked end straddles said second tensile element to overlap said second tensile element in said overlap region.

13. A tensile connector assembly according to claim 6, wherein said longitudinal tensile element includes a straight end portion, wherein said straight end portion is generally collinear with said tensile axis and wherein said straight end geometry overlaps said second tensile element in said overlap region.

14. A tensile connector assembly according to claim 6, wherein at least one of said longitudinal tensile element and said second tensile element includes a lateral offset portion, wherein said lateral offset portion is laterally offset from said tensile axis and wherein said lateral offset portion overlaps said second tensile element in said overlap region.

15. A tensile connector assembly according to claim 1, wherein said longitudinal tensile element includes high strength fibers.

16. A tensile connector assembly according to claim 15, wherein said high strength fibers are aligned to be generally parallel to said tensile axis.

17. A tensile connector assembly according to claim 15, wherein said high strength fibers are encapsulated in a matrix.

18. A tensile connector assembly according to claim 17, wherein said matrix is at least one of a thermoplastic polymer resin and a thermoset polymer resin matrix.

19. A tensile connector assembly according to claim 15, wherein said high strength fibers are continuous fibers.

20. A tensile connector assembly according to claim 19, wherein said fibers are unsupported dry fibers.

21. A tensile connector assembly according to claim 19, wherein said deformable connecting element is formed directly in said spoke, constituting an enlarged portion of enlarged cross-sectional geometry of said spoke and wherein said high strength fibers are encapsulated in a matrix and wherein said continuous fibers extend within said enlarged portion.

22. A tensile connector assembly according to claim 21, wherein said matrix is a thermoplastic polymer resin matrix.

23. A tensile connector assembly according to claim 19, wherein said high strength fibers of said longitudinal tensile element extend within said deformable connecting element.

24. A tensile connector assembly according to claim 23, including a second tensile element connected to said deformable connecting element, wherein said second tensile element includes a configured surface, with said deformable connecting element conforming to said configured surface, and wherein said configured surface is engaged to said deformable connecting element along said tensile axis.

25. A tensile connector assembly according to claim 1, wherein said deformable connecting element comprises hardened molding material, wherein said hardened molding material has a conformable and softened state and a solidified and hardened state.

26. A tensile connector assembly according to claim 25, wherein said deformable connecting element is formed in a mold.

27. A tensile connector assembly according to claim 26, including a second tensile element, wherein at least one of said longitudinal tensile element and said second tensile element constitutes an insert in an insert-molding process to form said deformable connecting element.

28. A tensile connector assembly according to claim 26, wherein said hardened molding material is formed via a high pressure molding process, selected from the series of injection molding and die casting.

29. A tensile connector assembly according to claim 26, wherein said longitudinal tensile element is integrally fixed to said hardened molding material.

30. A tensile connector assembly according to claim 26, wherein said longitudinal tensile element is adhered to said hardened molding material.

31. A tensile connector assembly according to claim 26, wherein said longitudinal tensile element welded to said hardened molding material.

32. A tensile connector assembly according to claim 25, including an outer collar adjacent said hardened molding material, wherein said outer collar constitutes at least a portion of said mold.

33. A tensile connector assembly according to claim 1, wherein said deformable connecting element includes an external surface and an internal surface and wherein said external surface is plastically deformed to press said internal surface of into gripping engagement with said longitudinal tensile element.

34. A tensile connector assembly according to claim 33, including at least one of a crimping means and a swaging means and a shrinking means as means for said deformation.

35. A tensile connector assembly according to claim 33, wherein said longitudinal tensile element includes a configured external surface and wherein said internal surface of said deformable coupling element is embossed by said longitudinal tensile element such that said deformable connecting element engages said longitudinal tensile element.

36. A tensile connector assembly according to claim 35, wherein said configured external surface includes helical threads.

37. A tensile connector assembly according to claim 33, wherein said internal surface of said deformable connecting element includes a configured surface and wherein said longitudinal tensile element is embossed by said internal surface such that said longitudinal tensile element engages said deformable connecting element.

38. A tensile connector assembly according to claim 37, wherein said configured surface includes helical threads.

39. A tensile connector assembly according to claim 33, including a second tensile element, wherein said deformable connecting element is plastically deformed to press said internal surface of said deformable connecting element into gripping contact with both said longitudinal tensile element and said second tensile element to couple said longitudinal tensile element with said second tensile element.

40. A tensile connector assembly according to claim 1, including an adhesive bond between said deformable connecting element and said longitudinal tensile element to provide resistance to pullout of said longitudinal tensile element due to said tensile load.

41. A tensile connector assembly according to claim 1, including a tensile load along said tensile axis, wherein said longitudinal tensile element includes a configured surface and wherein said deformable connecting element is engaged with said configured surface to create a mechanical interlock connection to provide resistance to pullout of said longitudinal tensile element due to said tensile load.

42. A tensile connector assembly according to claim 41, wherein said configured surface includes helical threads.

43. A tensile connector assembly according to claim 41, wherein said configured surface includes enlarged cross-sectional geometry.

44. A tensile connector assembly according to claim 1, wherein said longitudinal tensile element includes non-circular cross-section geometry to engage with corresponding geometry of said deformable connecting element to prevent rotation of said longitudinal tensile element with respect to said deformable connecting element about said tensile axis.

45. A tensile connector assembly according to claim 1, wherein said longitudinal tensile element extends through said deformable connecting element along said tensile axis to include at least two exposed portions.

46. A tensile connector assembly according to claim 45, wherein said at least two exposed portions constitute two structural tensile spans, wherein each of said two structural spans may independently support tensile loads.

47. A tensile connector assembly according to claim 1, including an auxiliary element that is connected to said tensile connector assembly, wherein said auxiliary element is engaged to said bracing element.

48. A tensile connector assembly according to claim 47, wherein said auxiliary element is threadably engaged to said tensile connector assembly.

49. A tensile connector assembly according to claim 48, wherein said auxiliary element is threadably engaged to said deformable connecting element.

50. A tensile connector assembly according to claim 49, wherein said deformable connecting element includes a smooth shank portion and wherein said auxiliary element includes an internally threaded surface and wherein said internally threaded surface of said auxiliary element is threadably engaged to said smooth shank portion to create a thread-forming threaded engagement between said auxiliary element and said deformable connecting element.

51. A tensile connector assembly according to claim 47, wherein said auxiliary element is threadably engaged to said bracing element.

52. A tensile connector assembly according to claim 47, wherein said deformable connecting element is embossed by said auxiliary element such that said deformable connecting element engages said auxiliary element.

53. A tensile connector assembly according to claim 47, including an overlie engagement of matched surface-to-surface bearing contact between a surface of said auxiliary element and a surface of said deformable coupling element, wherein said overlie engagement provides blocking to resist said tensile load.

54. A tensile connector assembly according to claim 1, wherein said deformable connecting element includes reinforcement fibers in a matrix.

55. A tensile connecting assembly according to claim 54, wherein at least a portion of said fibers are greater than 4 millimeters in length.

56. A tensile connector assembly according to claim 1, wherein said deformable connecting element constitutes an enlarged portion fixed to said longitudinal tensile element and wherein said enlarged portion provides an overlie engagement for connection between said deformable connecting element and said bracing element.

57. A tensile connector assembly according to claim 56 wherein said enlarged portion is formed directly into said longitudinal tensile element.

58. A tensile connector assembly according to claim 56, wherein said overlie engagement is a direct overlie engagement, including direct overlie engagement between said deformable connecting element and said bracing element.

59. A tensile connector assembly according to claim 56, including an auxiliary element, wherein said overlie connection occurs between said deformable connecting element and said auxiliary element.

60. A tensile connector assembly according to claim 1, wherein said deformable connecting element is welded to said longitudinal tensile element, including a fused surface interface between said deformable connecting element and said longitudinal tensile element.

61. A tensile connector assembly according to claim 60, wherein the means for said welding is ultrasonic welding, including the application of ultrasonic energy.

62. A tensile connector assembly according to claim 61, wherein said ultrasonic energy is applied to the deformable connecting element in a direction generally parallel to said tensile axis.

63. A tensile connector assembly according to claim 61, wherein said ultrasonic energy is applied to the deformable connecting element in a direction generally perpendicular to said tensile axis.

64. A tensile connector assembly according to claim 60, wherein the means for said welding is spin welding, including the application of frictional energy.

65. A tensile connector assembly according to claim 1, wherein said deformable connecting element includes non-circular external geometry to facilitate the rotational manipulation of said deformable connecting element about said tensile axis.

66. A tensile connector assembly according to claim 1, wherein said longitudinal tensile element is at least a portion of a vehicle wheel spoke and wherein said spoke has a first end connected to a hub and a second end connected to an outer rim and wherein said bracing element is one of said rim and said hub.

67. A tensile connector assembly according to claim 1, including an outer collar adjacent said deformable connecting element, wherein said outer collar provides reinforcement to said deformable connecting element.

68. A tensile connector assembly according to claim 1, including an engagement region between said deformable coupling element and said longitudinal tensile element and a depth of said engagement region along said tensile axis, wherein said depth of said engagement region is 4 times the average cross sectional thickness of said longitudinal tensile element in said engagement region.

69. A tensile connector assembly according to claim 1, wherein the material of said deformable coupling element is generally segregated from the material of said longitudinal tensile element.