Concrete Wall Frame Assembly With Stud-Welded Rod Connections
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Solution Overview
Problem
Conventional methods for constructing Concrete Filled Shear Walls (CFSW) using Concrete Wall Frames (CWFs) are labor-intensive and time-consuming due to the need for arc welding of metal rods, which results in protruding rod ends that can be restrictive in certain applications and require additional manufacturing steps.
Innovation Solution
The method involves stud welding one end of the metal rod to the inner surface of a continuous metal plate instead of arc welding, eliminating the need for holes in the first plate and allowing for a smoother exterior, combined with arc welding the other end to the second plate, reducing labor and time through the use of lighter and more maneuverable stud welding equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If arc welding is used to connect both ends of metal rods to metal plates, then structural integrity is achieved, but construction time and labor intensity increase
Solution Approach 1:
The patent divides the welding operation into two distinct segments: stud welding for connecting rod ends to one metal plate, and arc welding for connecting rod ends to the other metal plate. This segmentation allows optimization of each welding method for its specific application, using stud welding's speed advantage for one connection while maintaining arc welding's reliability for the other, thereby resolving the contradiction between structural integrity and construction speed
Solution Approach 2:
The patent changes the welding parameter (method type) based on the specific connection requirements. By selecting stud welding parameters (electrical contact, controlled heat input) for one plate connection and arc welding parameters (flexibility, penetration control) for the other, the patent achieves both rapid construction and reliable structural integrity, resolving the productivity-strength contradiction
2Ease of manufacture
If holes are drilled in both metal plates for rod insertion and arc welding, then rod connection is achieved, but the exterior surface becomes uneven and additional manufacturing steps are required
Solution Approach 1:
The patent extracts the hole-drilling requirement from one of the metal plates by using stud welding instead of arc welding through holes. The stud welding process allows the rod end to be welded directly to the plate surface without requiring穿透 holes, thereby maintaining the smooth exterior surface of one plate while still achieving secure rod connection
Solution Approach 2:
Instead of making both plates have holes for rod passage (conventional approach), the patent inverts the approach by having one plate without holes that receives the rod end via stud welding. This inversion eliminates the need for holes in one plate, preserving its smooth exterior surface while achieving the same rod connection function
3Ease of operation
If rod length is increased to allow protrusion for arc welding on both sides, then welding access is achieved, but material usage and footprint increase
Solution Approach 1:
The patent applies preliminary action by using stud welding to secure one end of the rod to the first metal plate before finalizing the connection at the second plate. This preliminary securing provides sufficient structural stability, eliminating the need for excessive rod length protrusion beyond the second plate for welding access, thereby reducing material usage while maintaining ease of operation
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 construction time and labor, eliminates the need for specific floor gaps and diagonal braces, provides a smaller footprint, and results in cost savings by reducing rod length and eliminating the need for additional manufacturing steps, while ensuring a smooth exterior surface.
Implementation Method 1
a first end of the rod is stud welded, as opposed to arc welded, to a respective one of the metal plates
Implementation Method 2
arc welding both ends of the rods
Data Source
AI summary
A concrete wall frame assembly and a method of manufacturing same is disclosed. The assembly includes two generally parallel metal plates and at least one rod extending between a first end and a second end. A first end of the rod is passed through a hole in the second plate toward the first plate until the first end engages a continuous inner surface of the first plate. The second end of the rod protrudes through the hole and extends past an outer surface of the second plate. A stud welder is connected to the either the second, protruding end of the rod, or connected to the rod between the two metal plates to stud weld the first rod end to the inner surface of the first plate. The second end of the rod is then arc welded to the second metal plate at the outer surface.