High-Strength Structural Connection Method Utilizing Helical Splines

Abstract

The present invention introduces a high-strength structural connection method for metal components in mechanical and civil engineering. The core of the technology relies on a self-locking mechanical interlock utilizing complementary outer and inner helical (spiral) splines and corresponding grooves. The assembled joint is rigidly fixed using thermal interference fitting (induction heating or cryogenic freezing), welding, forging, or mechanical threading. This combined approach ensures a uniform multi-axial spatial distribution of loads, effectively eliminating stress concentrators at the joint interface and shifting potential failure zones to the base material itself. The topological geometry, including the dimensions and the number of splines (e.g., 3, 4, or 6 massive splines), is fully scalable and adaptable to various structural elements, including different types of beams and complex mechanisms, depending on specific dynamic or static load requirements. Furthermore, the method is highly effective in tubular applications, where the interlocking spiral geometry withstands distributed pressure. The design also permits localized reinforcement of pipe walls at critical junctions using double-sided splines. Ultimately, this universal connection method provides unprecedented mechanical durability, structural stability, and resistance to extreme operational loads. 8 illustrations.