Annular Disc From Bent Sheet Material With Closed Junctions
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Solution Overview
Problem
Conventional methods for producing annular discs from sheet material are inefficient, as only a small percentage of the material is processed into usable discs, resulting in significant scrap and high reprocessing costs.
Innovation Solution
A method involving bending and severing sheet material to create annular discs with closed junctions, allowing for the connection of multiple parts to form complete discs, thereby maximizing material utilization and preventing bulging or buckling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If punching method is used to produce annular discs from sheet material, then production simplicity is maintained, but material utilization is poor (only 10-40% processed into discs)
Solution Approach 1:
The sheet material is divided into multiple narrower strips instead of attempting to punch complete annular discs from a single wide sheet. These strips are then formed into arc segments and joined together to create complete annular discs, allowing nearly 100% material utilization while maintaining production simplicity
Solution Approach 2:
The approach transitions from a two-dimensional punching operation to a three-dimensional forming process. Strips are bent into arcs and joined at junctions to form complete annular discs, utilizing the third dimension (depth/curvature) to achieve complete material utilization that was impossible with conventional punching
2Loss of substance
If bending sheet material into annular disc with closed junction is implemented, then material utilization increases significantly, but process complexity increases
Solution Approach 1:
The complex task of forming complete annular discs is segmented into manageable steps: cutting strips, forming individual arc segments, and joining them at junctions. This segmentation makes the overall complex process controllable and manufacturable
Solution Approach 2:
Arc segments are pre-formed from strips before being joined together. This preliminary forming action simplifies the final assembly process and ensures that each component is properly prepared before joining, reducing overall process complexity
3Loss of substance
If multiple parts are connected to form annular disc with multiple junctions, then material utilization is maximized, but manufacturing precision requirements increase
Solution Approach 1:
The annular disc is segmented into multiple arc parts that are joined at discrete junctions. This segmentation allows each part to be manufactured separately with standard tolerances, and the final assembly precision is managed through the junction connection design rather than requiring ultra-precise single-piece forming
Solution Approach 2:
Multiple arc segments are merged at their junctions to form the complete annular disc. The merging process is designed to accommodate normal manufacturing tolerances through proper joint design, ensuring that cumulative errors do not compromise the overall structural integrity or dimensional accuracy of the finished disc
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 approach significantly increases the percentage of material used in producing annular discs, reducing scrap and associated costs, while maintaining disc planarity and preventing manual unhooking issues.
Implementation Method 1
bending the sheet material into an annular disc
Implementation Method 2
closing the junction, so that an annular disc with a junction at which the annulus is closed is provided
Data Source
AI summary
The invention relates to an annular disc of bent sheet material (21) with at least one junction at which the annulus is closed. Furthermore, a method for producing an annular disc is disclosed, comprising the steps of: (a) providing a sheet material; (b) bending the sheet material into an annular disc; (c) severing the sheet material, so that an annular disc with a junction at which the annulus is open is provided; (d) closing the junction, so that an annular disc with a junction at which the annulus is closed is provided. A description is given of a method for producing an annular disc comprising the steps of: (i) providing a sheet material; (ii) bending the sheet material into a first part of an annular disc; (iii) severing the sheet material, so that a first part of an annular disc is provided; (iv) repeating steps (i), (ii) and (iii) at least once, so that at least one further part of the annular disc is provided; and (v) connecting the first part and the further parts of the annular disc, so that an annular disc with at least two junctions at which the annulus is closed is provided.