Cellular Board Fastening via Mechanical Joining
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Solution Overview
Problem
Traditional cellular board manufacturing is inefficient and expensive, particularly in fastening cores to surface plates, especially for large-area boards, and limits the production of cellular boards of varying sizes using the same raw materials.
Innovation Solution
The method involves assembling cellular boards from separate, thin metal profiles or lamellae, which are fastened together using fixing folds and various joining techniques such as machine seaming, gluing, or riveting, allowing for the creation of strong and flexible structures that can be easily manufactured in different sizes and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welding methods (laser welding or spot welding) are used to fasten cores to surface plates, then the structural strength is improved, but the manufacturing cost increases and the process becomes complex
Solution Approach 1:
The patent replaces thermal welding processes (laser welding, spot welding) with mechanical fastening methods such as self-tapping screws, rivets, or clips. This substitution eliminates the need for expensive welding equipment while achieving sufficient structural strength through mechanical interlocking and fastening forces.
Solution Approach 2:
The patent employs inexpensive fastening components such as self-tapping screws, rivets, or simple metal clips that can be quickly installed and removed if needed. These disposable or reusable fasteners are much cheaper than welding equipment and processes, reducing overall manufacturing costs while providing adequate structural integrity.
2Strength
If traditional welding methods are used to fasten cores to surface plates, then the structural strength is improved, but the manufacturing time and complexity increase
Solution Approach 1:
The patent replaces time-consuming welding operations with rapid mechanical fastening methods. Self-tapping screws can be driven quickly with simple tools, rivets can be set rapidly, and clips can be snapped into place, all of which are much faster than heating, melting, and cooling metal through welding processes.
Solution Approach 2:
The patent employs pre-formed cores with attachment features (such as pre-drilled holes, pre-formed flanges, or pre-attached fasteners) that allow for rapid assembly. The surface plates and cores are prepared in advance with matching fastening features, enabling quick connection without complex positioning or alignment during the fastening operation.
3Reliability
If hot galvanized steel plate is used as raw material, then the corrosion resistance is improved, but the coating can be damaged during traditional manufacturing processes
Solution Approach 1:
The patent replaces thermal welding processes with mechanical fastening methods that do not involve high heat. This avoids burning, melting, or discoloring the hot galvanized coating, preserving its corrosion-resistant properties. Mechanical fasteners are inserted or attached through pre-drilled holes or attachment points without applying damaging thermal energy to the coated surfaces.
Solution Approach 2:
The patent uses intermediary elements such as fasteners, clips, or attachment brackets that connect the galvanized steel components without direct thermal contact between the components themselves. These intermediaries are positioned between the surface plates and cores, allowing mechanical connection while protecting the galvanized coating from thermal damage.
4Area of stationary object
If cellular boards of large area are manufactured, then the application range is expanded, but the fastening difficulty increases particularly at the central part
Solution Approach 1:
The patent divides large-area cellular boards into modular sections or panels that can be manufactured separately and then assembled together. Each module contains its own cores and surface plates that are fastened using the simplified mechanical methods, and multiple modules are connected using similar fastening techniques at their interfaces, making large structures manageable through repetition of standardized, easy-to-fasten units.
Solution Approach 2:
The patent employs pre-assembled core-surface plate units or pre-fastened modular sections that are prepared in advance. These pre-assembled units are designed so that the fastening operations are performed on smaller, more manageable components rather than attempting to fasten entire large-area boards in one operation, reducing the difficulty of fastening at central and remote locations.
Data Source
AI summary
The object of the invention is a method for manufacturing cellular board (1), a cellular board, a method for producing cellular board element of steel plate strip, and a production line. A cellular board (1) according to the invention comprises a number of originally separate profiles (4, 6) of plate-like material, which have been fastened to each other. A single profile is intended to form in a finished cellular board a substantially planar first surface projection (6, 6′), a substantially planar second surface projection (6″, 6′″), a core (4, 4′), which is arranged to interconnect the first and second surface projections. In the cellular board (1) the profiles are fastened to each other so that in the adjacent lamellae the first surface projections (6, 6′) are located side by side and form thus a first surface plate (2) of the cellular board, the second surface projections (6″, 6′″) are located side by side and form thus a second surface plate (3) of the cellular board, the profile cores (4, 4′) form the core structure of the cellular board.