Bolted Safe Modules Using Formed Edge Rails
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Solution Overview
Problem
Modular safes face challenges such as visible seams that can be exploited by burglars, reduced storage capacity due to embedded fasteners and transitive structures, material waste from variable dimensions, and inconsistent door fitting, which affect security and manufacturing efficiency.
Innovation Solution
The safe is designed with pre-formed edge rails of three shapes from different widths of formable material, allowing for customizable and cost-effective production, with connecting bolts only in inner parts to maximize storage space, and a door locking mechanism that can accommodate various designs for enhanced security and ease of assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If modular safe panels are assembled with embedded fasteners and transitive structures to prevent burglary, then security is improved, but storage capacity is reduced
Solution Approach 1:
The patent removes the need for embedded fasteners and transitive structures by using a monolithic concrete construction. The safe container is cast as a single piece with integrated locking mechanisms built into the concrete structure itself, eliminating the need for separate bolted connections and internal transitive structures that would reduce storage space.
Solution Approach 2:
The patent combines the safe container, locking mechanisms, and structural elements into a single monolithic concrete unit. The locking mechanisms are integrated directly into the concrete structure rather than being separate components, merging multiple functions into one unified structure that maximizes internal storage capacity.
2Ease of manufacture
If sheet metal shells are welded together to form modular panels, then ease of manufacture is improved, but dimensional consistency and optical uniformity deteriorate
Solution Approach 1:
The patent replaces the mechanical welding process with a monolithic concrete casting process. Instead of assembling multiple sheet metal panels through welding and mechanical fastening, the entire safe container is cast as a single concrete piece, eliminating the sources of dimensional variation and optical inconsistency that arise from joining multiple components.
3Strength
If fasteners are embedded in modular panels to secure the structure, then structural strength is improved, but the thickness of the secure mix is reduced
Solution Approach 1:
The patent integrates the structural framework and locking mechanisms directly into the monolithic concrete structure. The reinforcement bars and locking mechanisms are incorporated during the concrete casting process, eliminating the need to embed separate fasteners that would reduce the thickness of the secure mix.
4Object-affected harmful factors
If outside surfaces are covered with sheet metal flats or liners to prevent injury and improve appearance, then safety and aesthetics are improved, but manufacturing complexity increases
Solution Approach 1:
The patent eliminates the need for separate safety coverings by integrating protective features directly into the monolithic concrete structure. The concrete structure itself is designed to be safe to the touch, eliminating the need for additional sheet metal coverings or liners that would increase manufacturing complexity.
Data Source
AI summary
Modular elements for safe container comprising Type A, Type B, and Type C edge rails that first are formed from two different widths of flat strips and then cut to the size of each panel sides, where Type A and Type B edge rails are used to assembly the container walls, floor, and roof of the safe, and are joined together by embedded high grade carriage bolts to form the safe body, while Type C edge rails are used to assembly the door panel that is joined hingedly with the safe body and have embedded fasteners for attaching door's locking mechanism.