Single-Piece Braided Metal Structure Manufacturing
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Solution Overview
Problem
The existing method of manufacturing braided metal structures, such as chairs, is costly due to the need for extensive welding and prone to rust and breakage, limiting its applications due to the lack of connection between overlapping metal strips.
Innovation Solution
A method involving the formation of holes in a solid metal plate using punches, followed by deep drawing operations in specific patterns to create longitudinal strips without overlaps, allowing for continuous automation and varied shapes, using a numerically controlled machine to shape the metal into a single-piece braided structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding operations are used to join overlapping metal strips, then the structural integrity is improved, but the manufacturing cost and complexity increase significantly
Solution Approach 1:
The patent extracts and eliminates the welding operation from the manufacturing process. Instead of joining separate metal strips through welding, the invention forms the entire braided structure as a single continuous piece of metal through deep drawing operations, removing the need for welding equipment and operations entirely
Solution Approach 2:
The patent merges multiple separate metal strip components into a single unified structure. By forming the braided pattern from one continuous metal sheet through deep drawing, the invention combines what would otherwise be separate welded components into one integrated piece, eliminating joint weaknesses
2Reliability
If multiple welding operations are performed to join metal strips in different planes, then the structural connection is improved, but the manufacturing time and cost increase
Solution Approach 1:
The patent performs preliminary forming actions by creating the complete braided three-dimensional pattern through deep drawing operations before any assembly or joining is required. The interlocking structure is formed in advance during the shaping process itself, eliminating the need for subsequent welding operations to connect components
Solution Approach 2:
The patent maintains continuous useful action by forming the entire braided structure in a single continuous deep drawing process without interruption for welding or assembly operations. The metal sheet is continuously transformed into the final braided shape through sequential deep drawing steps, maximizing manufacturing efficiency
3Ease of manufacture
If metal strips are left unjoined in overlapping parts, then the manufacturing process is simplified, but the appearance deteriorates with frequent rust and breakage zones
Solution Approach 1:
The patent merges overlapping metal strip sections into a single continuous metal structure through deep drawing. The overlapping regions that would normally be separate unjoined surfaces are instead formed as continuous integral portions of the same metal sheet, eliminating the rust and breakage zones associated with unjoined overlaps
Solution Approach 2:
The patent creates a homogeneous structure where the entire braided object is made from one continuous piece of metal with uniform properties throughout. This eliminates the heterogeneity of unjoined overlapping sections that have different structural characteristics and are more susceptible to environmental degradation
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 reduces manufacturing costs and eliminates rust and breakage issues, enabling the production of braided metal products with diverse shapes and decorations, suitable for various applications like furniture and displays, while maintaining a unified, non-degradable surface.
Implementation Method 1
formation of a plurality of holes (10a) in a pre-established and memorized position, the holes being of a configuration established and obtained with the aid of appropriate punches
Implementation Method 2
carrying out a deep drawing operation in a longitudinal direction of the plate, according to a defined band
Implementation Method 3
The deep drawing operations are carried out using a numerically controlled machine capable of carrying out the aforementioned operations
Data Source
AI summary
The fabrication of braided metal structures comprises : (A) forming a number of holes in a plain metal plate (10) in pre-established and memorized positions; (B) stamping on a half thickness of the plate, blow by blow, along a pre-established mesh to the place between two consecutive holes; (C) realizing, by staggering, all the stampings in the longitudinal plane to delimit the array of longitudinal bands; (D) proceeding with a second stamping in a different plane to form a number of bands in the same plane to form the assembly of useful plate surface and the corresponding mesh. An independent claim is also included for the braided metal structure.