Bead Chain Forming with Laser Welded Semi-Spherical Halves

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Solution Overview

Problem

Existing bead chains are prone to breaking due to ineffective interlocking between beads, often occurring at links, which compromises their security and durability.

Innovation Solution

A method of forming a bead chain by creating spherical beads with semi-spherical halves and interconnected links, where the beads are laser-welded together using a hinge connection and dumbbell-shaped links to enhance interlocking, ensuring secure engagement and stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional interlocking methods are used for bead chains, then the manufacturing process is simple, but the chain breaks easily at links due to ineffective interlocking

Engineering Contradiction:

Improvechain durabilityVSAvoidinterlocking structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The bead is divided into two semi-spherical halves that can be opened and closed to accommodate the link, allowing the link to be inserted and then securely enclosed. This segmentation enables effective interlocking while maintaining manufacturing feasibility through progressive forming of the flat stock into semi-spherical shapes with open recesses.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The link is positioned within the recesses of the semi-spherical bead halves, with the enlarged ends of the link engaging on the inside of the circular edge of adjacent semi-spherical halves. This nesting arrangement ensures the link is securely enclosed by the bead halves, preventing chain breakage at the link while integrating the components efficiently.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Strength

If laser welding is used to join bead halves, then the interlocking strength is significantly improved, but the manufacturing complexity and cost increase

Engineering Contradiction:

Improveinterlock strengthVSAvoidmanufacturing simplicity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Traditional mechanical fastening methods are replaced with laser welding to join the semi-spherical bead halves. This substitution provides superior joint strength and reliability while the progressive forming process maintains manufacturing efficiency by forming both the bead and link concurrently from flat and wire stock.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The joining method transitions from mechanical interlocking alone to laser welding, changing the physical-chemical state of the material at the joint. Laser welding creates a metallurgical bond between the bead halves, significantly enhancing the interlock strength and preventing chain failure at the connection points.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the bead halves are closed tightly to secure the link, then the interlocking becomes more secure, but the manufacturing precision requirements increase

Engineering Contradiction:

Improveinterlocking securityVSAvoidbead half alignment precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The link is positioned within the open recesses of the semi-spherical bead halves before the halves are closed and welded. This preliminary positioning ensures proper alignment and secure engagement of the link with the bead halves, reducing the precision requirements for the closing and welding operations while maintaining interlocking security.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The recesses are formed with specific local geometries that accommodate the link's enlarged ends, creating localized engagement zones. This local quality design ensures secure interlocking at critical points while allowing tolerance in other areas, reducing overall manufacturing precision requirements while maintaining reliability.

Inventive Principle:

Principle #3Local quality

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

The method provides a secure and durable bead chain with improved interlocking between beads, significantly reducing the likelihood of breakage and enhancing the chain's overall strength and reliability.

Implementation Method 1

laser welding between the connected semi-spherical bead halves

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Data Source

PatentUS8904744B1Method of forming a bead chain

Publication Date: 2014.12.09 NATIONAL CHAIN CO

AI summary

The method includes providing a source of flat stock; forming the flat stock into a spherical shaped bead that includes connected semi-spherical bead halves with each half having opposed open recesses that are located in a circular edge that defines each semi-spherical half; providing a source of wire stock; forming the wire stock into a series of the interconnected links with each link having a middle section and contiguous opposed enlarged ends at respective ends of the middle section; positioning the formed links each between adjacently disposed spherical shaped beads for accommodation in facing recesses thereof; closing the connected semi-spherical bead halves to form the spherical shaped bead; and laser welding between the connected semi-spherical bead halves.