Asymmetrical Edge Transition for Core Component Robustness
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Solution Overview
Problem
Existing core components in inductive construction elements often have sharp edges that are prone to fissuring under mechanical or thermal loading, and manufacturing processes can introduce density variations leading to stress peaks and reduced robustness.
Innovation Solution
A core component with a non-symmetrical transition between surfaces, where the edge dimensions are dissimilar and optimized to reduce stress and prevent fissures, featuring a transition with a larger extent in the direction of higher tensile stresses and a contour that minimizes density variations, such as a parabolic or rectilinear shape with rounded regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a sharp edge is used in the core component, then the manufacturing process is simple, but the edge is prone to fissuring under mechanical or thermal loading
Solution Approach 1:
The patent applies asymmetry by configuring the transition at the edge to be non-symmetrical rather than symmetrical. The transition has different first and second edge dimensions, where the first edge dimension extends in a first direction perpendicular to the edge profile, and the second edge dimension extends in a second direction perpendicular to both the edge profile and the first direction. This asymmetric configuration optimizes stress distribution by providing different transition extents in different directions, preventing fissures while maintaining manufacturing feasibility.
Solution Approach 2:
The patent applies curvature by replacing the sharp edge with a rounded transition. The transition features rounded regions that eliminate stress concentration points inherent in sharp edges. The first and second edge dimensions define the extent of this rounded transition in perpendicular directions, creating a smooth, curved profile that distributes mechanical and thermal stresses evenly, thereby preventing fissuring while maintaining structural integrity.
2Ease of manufacture
If a symmetrical rounding or chamfer is used at the edge, then the manufacturing process is straightforward, but mechanical stresses and stress peaks are not adequately reduced
Solution Approach 1:
The patent replaces symmetrical rounding or chamfer with an asymmetric transition configuration. The first edge dimension and second edge dimension are deliberately made different, allowing the transition to provide optimal stress relief in directions where tensile stresses are highest. This asymmetric design targets stress concentration points more effectively than symmetrical transitions while remaining manufacturable through standard processes.
Solution Approach 2:
The patent applies local quality by making the transition properties direction-dependent. The first edge dimension is optimized for stress relief in the first perpendicular direction, while the second edge dimension is optimized for the second perpendicular direction. This localized optimization of transition geometry allows different parts of the same edge to have different dimensional characteristics suited to their specific stress conditions.
3Reliability
If density variations are minimized in the manufacturing process, then the robustness of the core component is improved, but the geometric properties and transition shape require precise optimization
Solution Approach 1:
The asymmetric transition configuration with different first and second edge dimensions is designed to compensate for density variations that occur during manufacturing. By providing different transition extents in different directions, the design creates a more tolerant geometry that can accommodate manufacturing variations without creating stress concentration points, thereby maintaining robustness even when precise control of density distribution is challenging.
Solution Approach 2:
The patent optimizes specific geometric parameters of the transition, namely the first edge dimension and second edge dimension, to achieve robustness. These parameters are carefully selected and optimized to minimize stress concentration and accommodate density variations. The optimized parameter values balance the competing requirements of robustness and manufacturability, providing a design that is resilient to manufacturing imprecisions.
Data Source
AI summary
A core component is disclosed. In an embodiment, the core component includes at least one edge that has a transition, wherein the transition is asymmetrical.