Acoustic Baffle Element With Plastic Deformed Locking Profiles
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Solution Overview
Problem
Conventional soundproof wall elements require significant manufacturing effort due to the need for rivets, screws, or welded connections, which are costly and time-consuming, especially in areas exposed to periodic stresses from air displacement by passing vehicles.
Innovation Solution
The soundproof wall elements feature a U-shaped groove system where the edge region is connected via positive connections formed by joint plastic deformation, eliminating the need for additional connecting means like screws or rivets, while maintaining load capacity, and allowing for precise assembly and varied connection types to manage different forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fastening methods (rivets, screws, welds) are used to connect components in overlapping areas, then the load-bearing capacity and reliability of connections are improved, but the manufacturing effort and complexity increase significantly
Solution Approach 1:
The patent merges the connection function into the structural components themselves by forming integral locking profiles directly on the side walls and chords. The locking profiles are created by bending or folding the metal sheets during forming, eliminating the need for separate fasteners and reducing manufacturing steps while maintaining reliable connections under periodic loads.
Solution Approach 2:
The patent introduces locking profiles as intermediary structural features that mediate the connection between overlapping components. These profiles engage with corresponding grooves or slots in adjacent components, providing a reliable mechanical interlock that distributes loads across the connection area without requiring additional fasteners.
2Strength
If additional fasteners and connecting means are used to ensure stable connections, then the strength and durability of the structure are improved, but the manufacturing cost and production time increase
Solution Approach 1:
The patent implements self-service connection through integral locking profiles that are formed as part of the structural components during the sheet metal forming process. The profiles automatically engage with corresponding features in adjacent components, providing self-aligning and self-securing connections that eliminate the need for separate fastening operations and improve manufacturing productivity.
Solution Approach 2:
The locking profiles are pre-formed into the structural components during the initial sheet metal forming process, before assembly. This preliminary action ensures that the connection features are already in place and properly positioned, allowing for rapid assembly without requiring additional fastening steps during the assembly process.
3Ease of manufacture
If simple connection methods are used to reduce manufacturing effort, then the ease of manufacture is improved, but the load-bearing capacity and fatigue resistance of connections may be compromised
Solution Approach 1:
The patent optimizes the geometric parameters of the locking profiles, including their shape, size, and positioning, to ensure they can withstand periodic loads and fatigue conditions. The profiles are designed with appropriate thickness, curvature radius, and engagement depth to distribute stresses and prevent fatigue failure while maintaining ease of manufacture through standard sheet metal forming 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
This solution reduces manufacturing costs and effort by simplifying the assembly process and enhancing the stability of connections between elements, allowing for durable and fatigue-resistant bonds without compromising load capacity.
Implementation Method 1
the positive locking connection is formed by a common plastic deformation of at least one of the legs and the edge region received in the groove
Data Source
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AI summary
An element (1) for a noise barrier with a longitudinal extent (L) has two side walls (2) extending in the direction of the longitudinal extent (L), each with an upper longitudinal edge (6) and a lower longitudinal edge (7). Furthermore, the element (1) has an upper chord (3) extending in the direction of the longitudinal extent (L) and located in the region of the upper longitudinal edges (6), with two lateral edges (8) extending in the direction of the longitudinal extent (L), and/or a lower chord (4) extending in the direction of the longitudinal extent (L) and located in the region of the lower longitudinal edges (7), with two lateral edges (9) extending in the direction of the longitudinal extent (L).An edge region (20) of at least one of the longitudinal edges (6, 7) of at least one of the side walls (2) extends in the direction of the longitudinal extent (L) along a lateral edge (8, 9) of the upper chord (3) or the lower chord (4) and is arranged overlapping a leg (26) of the lateral edge (8, 9), or an edge region (20) of at least one of the lateral edges (8, 9) of the upper chord (3) or the lower chord (4) extends in the direction of the longitudinal extent (L) along a longitudinal edge (6, 7) of one of the side walls (2) and is arranged overlapping a leg (26) of the longitudinal edge (6, 7). The edge region (20) is connected to the leg (26) via at least one positive-locking connection (11), wherein the positive-locking connection (11) is formed by a common plastic deformation of the leg (26) and the edge region (20).