Combined Sheet Interlock Structure for Separation-Resistant Joints
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Solution Overview
Problem
Existing sheet materials joined using single-directional indentation features tend to separate over time due to deformation of joints, leading to disassembly of finished products, as the joining forces from mechanical press operations weaken.
Innovation Solution
A combined sheet design featuring main and foundation sheets with indentation features oriented in different directions, where the first main indentation feature provides a first overhang and the second main indentation feature provides a second overhang, both crimped with corresponding foundation indentation features, preventing separation by requiring deformation of the indentation features for separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If single-directional indentation features are used to join sheet materials, then the joining process is simple, but the joints deform and separate over time
Solution Approach 1:
The patent employs asymmetric indentation features with different orientations (first and second directions) that are not uniform in their geometric arrangement. This asymmetry creates interlocking patterns that resist separation forces more effectively than symmetric, single-directional indentations, directly addressing the reliability issue while maintaining manufacturing simplicity.
Solution Approach 2:
The invention transitions from single-directional to multi-directional indentation features, adding dimensional complexity to the joining pattern. By incorporating indentations in multiple directions (first direction and second direction), the joint resistance becomes three-dimensional and more robust against separation forces, resolving the contradiction between simplicity and reliability.
2Ease of manufacture
If mechanical press operations are used to join sheets, then the joining process is straightforward, but the joining forces weaken over time
Solution Approach 1:
The patent creates preliminary interlocking structures through multi-directional indentation features before any separation forces act on the joint. The crimped and interlocked geometry is pre-formed during manufacturing, establishing a robust mechanical connection that maintains its integrity over time, counteracting the weakening effect of cyclic environmental conditions.
Solution Approach 2:
The joining system is segmented into multiple independent indentation features oriented in different directions rather than relying on a single joining mechanism. This segmentation distributes the joining forces across multiple directional vectors, preventing any single joint from bearing the full load and thereby maintaining durability over time.
3Device complexity
If indentation features are used without adhesives, then the design is simple, but the sheets may separate under stress
Solution Approach 1:
The indentation features are designed to be self-interlocking through their geometric configuration, with no external adhesives or bonding materials required. The crimped and interlocked pattern creates a self-sustaining mechanical connection that derives its strength from the geometry itself, maintaining design simplicity while achieving adequate connection strength.
Solution Approach 2:
The patent creates a composite joint structure where the main sheet and foundation sheet form an integrated assembly through the interlocking indentation features. This composite arrangement combines the mechanical properties of both sheets with the geometric interlock, achieving connection strength comparable to or exceeding adhesive bonds without the complexity of additional materials.
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 combined sheet design effectively prevents separation of the foundation sheet from the main sheet even when joints deform, maintaining structural integrity without the need for adhesives or additional bonding materials.
Implementation Method 1
the first foundation indentation feature being crimped to the first main indentation feature and the second foundation indentation feature being crimped to the second main indentation feature
Data Source
AI summary
Combined sheets and a method of producing combined sheets. A combined sheet includes a main sheet including a first main indentation feature providing a first overhang over a first portion of the main sheet and a second main indentation feature providing a second overhang over a second portion of the main sheet. The combined sheet also includes a foundation sheet abutting the main sheet. The foundation sheet includes a first foundation indentation feature crimped to the first main indentation feature and a second foundation indentation feature crimped to the second main indentation feature. The first overhang and the second overhang provides overhangs in different directions to prohibit separation of the foundation sheet from the main sheet. The method of producing the combined sheet includes co-locating the main sheet to abut the foundation sheet and pressing one or more indentation punches for forming indentation features providing overhangs in different directions.