Corner Bearing Segmentation Reduces Sheet Metal Waste
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Solution Overview
Problem
Existing corner bearing designs require a recess in frame materials, are costly due to molded body production, and result in sheet metal waste, limiting their applicability and efficiency.
Innovation Solution
A corner bearing design where the threaded sleeve with the attached bolt is positioned between already fastened cheeks, allowing for surface treatments and horizontal adjustment, featuring a stepped bore and collars for non-rotatable coupling, and a deformable section for torque-proof assembly, enabling adjustability and reduced waste through separate production and welding of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the corner bearing is produced as a molded body, then the structural integrity is improved, but the production cost increases and post-processing is required
Solution Approach 1:
The corner bearing is divided into separate components: a base plate and two cheeks that are produced separately by stamping and bending, then joined together. This segmentation allows each component to be manufactured using cost-effective stamping processes rather than expensive molded body production, while maintaining structural integrity through proper joining of the segments.
2Stability of the object's composition
If the base plate is designed with wide dimensions to provide stability, then the structural stability is improved, but the sheet metal waste increases
Solution Approach 1:
The base plate is divided into a central body and separate ear portions that form the cheeks. This segmentation allows the central base plate to be minimized in size for stability, while the cheeks are formed separately from the ears, optimizing material usage and reducing overall sheet metal waste.
Solution Approach 2:
The cheeks are formed by folding the ear portions of the base plate itself, creating a nested structure where the cheeks are integrated into the base plate design. This nesting approach minimizes the overall material required while maintaining the necessary stability and structural features.
3Adaptability or versatility
If the cheeks are fastened separately from the base plate, then the manufacturing flexibility is improved, but the assembly complexity increases
Solution Approach 1:
The cheeks are formed by folding the ear portions of the base plate and joining them to the central body through welding or other joining methods. This merging approach combines the base plate and cheeks into a single integrated structure that maintains manufacturing flexibility while reducing assembly complexity compared to completely separate components.
4Manufacturing precision
If the corner bearing requires a recess in frame materials, then the installation precision is improved, but the applicability to different frame materials decreases
Solution Approach 1:
The corner bearing is designed with a base plate and separate cheek components that can be adapted to different frame materials and configurations. The universal design allows the same basic structure to be installed in various frame types by adjusting the mounting configuration, eliminating the need for specific recesses in the frame materials while maintaining installation precision.
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 design enhances adjustability, reduces production costs, and minimizes waste by allowing surface treatments and efficient assembly, while ensuring stability and non-rotatable coupling, making it suitable for various frame materials and applications.
Implementation Method 1
the bolt has a deformable section on its free end associated with the head part, which engages behind the stepped shoulder in the deformed state
Data Source
Figure 1a~2
Figure 3
Figure 4
AI summary
The hinge has a corner bearing block (1) secured at a frame and connected with a corner tape through a threaded bore of a spindle (5), where the corner tape is assigned to a wing. The bearing block is engaged with a corner bearing bolt (6) in the corner tape. The spindle comprises a mushroom-shaped bolt and a sleeve-like head part assigned to the mushroom-shaped bolt, which is engaged with a shaft end. The mushroom-shaped bolt and the sleeve-like head part are engaged with a threaded sleeve that is rotatably coupled with mushroom-shaped bolt and the head part in a torque-proof manner.