Curved Support Structure Alignment and Thermal Insulation
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Solution Overview
Problem
Existing methods for manufacturing support structures with curved elements face challenges in achieving stable and firm joints due to curvature, and result in structures with high heat conductivity, which may not be desirable.
Innovation Solution
The method involves providing alignment structures on the first and second elements to ensure accurate mutual alignment during joining, allowing for a firm and irreversible connection, and using materials with varying thermal conductivities to achieve a strong, thermally insulating structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If curved elements are joined together to form complex shapes, then manufacturing versatility and shape complexity are improved, but joining stability and firmness deteriorate due to curvature making it difficult to hold elements stably during welding
Solution Approach 1:
Alignment structures (protrusions and recesses) are pre-formed on the elements before joining. These preliminary structural features ensure proper positioning and stable holding of curved elements during the joining process, resolving the instability caused by curvature while maintaining manufacturing versatility for complex shapes
2Strength
If metal elements are used to form strong structures, then structural strength is improved, but thermal insulation performance deteriorates due to high heat conductivity of metal
Solution Approach 1:
The support structure uses composite construction with metal elements providing structural strength and plastic elements providing thermal insulation. This combination allows the structure to simultaneously achieve high strength from metal components while reducing heat conductivity through insulating plastic elements, particularly at joints and connecting pieces
3Manufacturing precision
If alignment structures are added to ensure accurate joining, then joining precision is improved, but manufacturing complexity increases
Solution Approach 1:
The alignment function is segmented into simple protrusion and recess features that are integrated into the element geometry. These segmented alignment features provide precise positioning without requiring complex alignment mechanisms, maintaining manufacturing simplicity while achieving high joining accuracy
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 enhances manufacturability, reduces costs, and produces a durable, elegant system with improved thermal insulation and structural strength, capable of forming complex shapes suitable for various applications, including building frameworks.
Implementation Method 1
The first side surface of the first element and the first lateral edge of the second element are provided with an alignment structure for mutual alignment during joining
Implementation Method 2
The elements are attached to each other by laser beam welding
Implementation Method 3
one or more of the elements can be made from or consists of non-metal material, for example a thermally insulating material
Data Source
AI summary
Method for manufacturing a support structure including: - providing at least a first flat elongated element (1) having a curvature in a corresponding first plane (P1) that is substantially in parallel with respect to faced-away longitudinal side surfaces of that element (1); - providing at least a second flat elongated element (2), to be joined with a said first element (1), the second element (2) having a curvature in a second corresponding plane (P2) that extends substantially in parallel with respect to faced-away longitudinal side surfaces of that element (2); - further curving both the first elongated element (1) and a respective second element (2) by bending the respective element (1, 2) out of the respective first and second plane (P1, P2) such that they can be joined with a first side surface of the first element (1) receiving a first lateral edge of the respective second element (2); and - joining at least the first element (1) and respective second element (2).