Container Upper Plate Handle Mounting Without Weld Corrosion
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Solution Overview
Problem
Conventional methods for manufacturing container upper plates with handles, which use welding, result in corrosion and reduced coupling force, especially when handling heavy liquids or powders, leading to inefficiencies and potential damage.
Innovation Solution
A method and apparatus that form projections on the steel plate and corresponding grooves or holes in the holding plate, allowing for secure coupling under pressure without welding or adhesives, using a steel-plate-shaping unit and coupling unit to press-fit the components together, enhancing the coupling force and preventing corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If welding is used to couple the holding plate to the upper plate, then the coupling process is simple and efficient, but the tin-plated portion is damaged and the welded portion corrodes
Solution Approach 1:
The patent replaces the welding process (thermal/chemical system) with a mechanical press-fit system. Projections on the holding plate are pressed into corresponding grooves or holes in the upper plate through a press-fit unit, achieving coupling without welding. This mechanical substitution eliminates the harmful thermal effects that damage the tin-plated surface and cause corrosion.
Solution Approach 2:
The patent introduces projections and grooves as intermediary coupling elements. The projections on the holding plate fit into grooves or holes in the upper plate, creating a mechanical interlocking system that serves as an intermediary between the two components. This intermediary mechanism enables secure coupling without direct welding contact, preventing corrosion while maintaining coupling efficiency.
2Ease of manufacture
If spot-welding is used to couple the holding plate to the upper plate, then the manufacturing process is straightforward, but the coupling force decreases when heavy liquids or powders are stored
Solution Approach 1:
The patent segments the coupling interface into multiple engagement points through projections and corresponding grooves or holes. Instead of relying on a single welded area, the mechanical interlocking system distributes the coupling force across multiple projection-groove interfaces. This segmentation enhances the overall coupling strength to support heavy contents while maintaining manufacturing simplicity.
Solution Approach 2:
The projections are designed with curved surfaces that fit into the grooves or holes, creating a form-interlocking mechanism. The curved geometry of the projections provides mechanical engagement that resists pull-out forces better than flat welded surfaces, thereby increasing coupling strength while keeping the manufacturing process straightforward.
3Strength
If welding is used to attach the handle to the upper plate, then the handle is securely attached, but the upper plate becomes damaged and corroded at the welded portion
Solution Approach 1:
The patent replaces the welding system with a mechanical press-fit system for handle attachment. The holding plate with projections is pressed into the upper plate through a press-fit unit, creating a secure mechanical connection without thermal welding. This substitution maintains strong handle attachment while eliminating the corrosion and damage caused by welding at the attachment location.
Data Source
AI summary
An apparatus and method for manufacturing a container upper plate including a handle coupled thereto are disclosed. The apparatus includes a steel-plate-shaping unit for forming at least one projection on an upper surface of a steel plate, a holding-plate-supply unit for supplying a holding plate including a reception portion, and a mounting portion bilaterally extending from the reception portion and coupled to the steel plate, the mounting portion having at least one groove or at least one hole formed therein, to the steel-plate-shaping unit, a loading unit for loading the holding plate onto the steel plate such that the at least one projection on the steel plate is fitted into the at least one groove or the at least one hole, and a coupling unit for coupling the holding plate to the steel plate by pressing a fitted portion by means of a press plate.


