Folded Door Leaf Manufacturing with Hidden Interlocking Grips
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Solution Overview
Problem
Existing methods for producing rebated door leaves in box and cover construction are complex and prone to visible connections or exposure to negative external influences, making them difficult to manufacture and optically undesirable.
Innovation Solution
A method involving folding parallel edge regions to form gripping devices that engage behind each other within parallel rabbets, with additional edge regions forming receiving grooves and tongues for secure connection without visible exposure, allowing for displacement during assembly and eliminating the need for further forming steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If rear hooking devices are arranged in the rebate area to form a firm connection between box and cover, then connection stability is improved, but the manufacturing process becomes complex requiring pre-bending and multiple folding steps
Solution Approach 1:
The gripping devices are formed by folding the edge regions during the initial manufacturing process, preparing the connection structures in advance. The box and cover are then simply placed on top of each other and connected by pressing, eliminating the need for complex multi-step processes while maintaining firm connection stability.
Solution Approach 2:
The folding of edge regions automatically forms the gripping devices that engage with each other during assembly. The structure self-organizes the connection elements through the folding process itself, eliminating the need for separate complex forming operations and reducing manufacturing steps.
2Ease of manufacture
If rear hooking devices are arranged next to the rebate area, then manufacturing process is simplified, but connections become visible and exposed to external influences
Solution Approach 1:
The gripping devices are nested within the rebate area itself, with the folded edge regions forming connection structures that are hidden inside the rebate. This positioning conceals the connections from external view while protecting them from environmental influences, and the folding process remains relatively simple.
3Strength
If multiple folding steps are performed to create gripping devices in the rebate area, then connection firmness is improved, but production time and cost increase
Solution Approach 1:
The gripping devices are formed as integral parts of the box and cover during the initial folding process. The edge regions are folded to create the connection structures in advance, so that when the box and cover are assembled, the firm connection is achieved immediately without requiring additional complex forming steps, thus maintaining production efficiency.
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
The method involves folding two parallel edge areas at appropriate parallel edges of a box metal sheet (12) and a lid metal sheet (14). An edge portion (54) of the box metal sheet and the lid metal sheet is folded. A spring (72) is inserted into a receiving groove (58) along the displacement direction. The box metal sheet and the lid metal sheet are connected with each other through interlocking hook portions of rear gripping elements, until the spring is connected with the receiving groove. An independent claim is included for door leaf.