Solid State Joining of Angled Edges with Welded Members
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for joining large structures result in significant scrap or waste material, leading to inefficiencies and increased costs due to the need for machining and removal of excess material.
Innovation Solution
A solid state method involving the use of angled edges, welded angled joining members, and a plug member to form a solid state joined structure, minimizing excess material by creating a continuous structure with reduced scrap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If large structures are produced by machining from even larger pieces of material, then the desired structure can be obtained, but a large amount of scrap or waste material is generated which is costly and inefficient
Solution Approach 1:
The patent divides the structure into multiple separate pieces that are joined together using solid state joining methods. Instead of machining a single large piece, the structure is segmented into smaller components that can be efficiently manufactured and then assembled, dramatically reducing scrap material while maintaining structural integrity
Solution Approach 2:
The patent combines multiple separately manufactured structure pieces into a unified continuous structure through solid state joining. The joining members and plug members merge the separate components into an integrated assembly that functions as a single continuous structure, eliminating the need to machine from one large piece
2Loss of substance
If solid state joining method is used to decrease scrap material, then material efficiency is improved, but the joining process complexity increases with multiple steps including angled edges, joining members, holes, and plug members
Solution Approach 1:
The patent performs preliminary actions by pre-configuring the angled edges on structure pieces and pre-positioning the joining members before final assembly. The angled edges are machined in advance, and joining members are prepared with corresponding angles, allowing for efficient assembly without complex real-time adjustments
Solution Approach 2:
The patent introduces joining members and plug members as intermediary elements that facilitate the connection between structure pieces. These intermediaries simplify the joining process by providing standardized connection interfaces, making the overall process more manageable despite the multiple steps involved
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 method effectively joins structures with minimal scrap, allowing for the production of large, continuous structures of various sizes and configurations while reducing material waste and production costs.
Implementation Method 1
the angled joining members are welded between the adjacent angled edges of the at least two structures
Implementation Method 2
a plug member is forced at least partially into the at least one hole
Data Source
AI summary
Under one step of one embodiment of a solid state method for joining structures, angled edges of at least two structures are disposed adjacent to one another. In another step, a plurality of angled joining members are disposed adjacent to one another between the adjacent angled edges of the at least two structures. In still another step, the angled joining members are welded between the adjacent angled edges of the at least two structures. In yet another step, at least one hole is formed into and extended between adjacent edges of the welded angled joining members. In an additional step, a plug member is forced at least partially into the at least one hole.