Grate Structural Element Using Folded Strip Coils
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Solution Overview
Problem
Existing grates, such as those with U-shaped chords and zigzag webs, are limited in shape variability, obstructive, and complex to produce due to their structural design, making them unsuitable for diverse applications and manufacturing processes.
Innovation Solution
A grate composed of interconnected coils formed from a flat strip folded along angled lines, allowing for easy shaping, connection, and expansion, with coils that can spiral in different directions and have varying cross-sections, enabling a wide range of dimensions and appearances without the need for intertwining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If U-shaped chords and zigzag web are used to form a girder, then structural strength is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The structural element is segmented into repeating coil units formed from a continuous strip. Each coil consists of multiple windings with flat parts connected by fold lines, creating modular segments that can be easily manufactured and assembled while maintaining structural integrity through the interconnected coil design.
2Strength
If U-shaped chords are used in the girder, then structural strength is improved, but ease of operation and view through the girder deteriorate
Solution Approach 1:
The straight chords are replaced with curved coil structures formed by folding the strip along angled fold lines. The coils create a curved, open structure that maintains structural strength through the folded geometry while allowing light and view to pass through the continuous open space in the center of each coil winding.
3Strength
If traditional girder structure with chords and web is used, then structural strength is improved, but adaptability to different shapes and applications deteriorates
Solution Approach 1:
The coil structure serves multiple functions: it provides structural strength through the folded geometry, creates open spaces for visibility and light transmission, and can be configured in various patterns (parallel, alternating directions) for different applications. The same basic coil unit can be adapted to create grates, fences, partitions, or decorative elements.
Solution Approach 2:
The structure allows for dynamic configuration where coils can be arranged in different patterns, orientations, and densities. Coils may spiral in the same or opposite directions, and the spacing between coils can be varied to create different levels of openness and structural characteristics, enabling adaptation to diverse design requirements.
4Shape
If alternating first and second pairs of bends with different angles are used, then shape complexity is improved, but ease of manufacture deteriorates
Solution Approach 1:
The fold lines are positioned at specific locations along the strip, creating localized folding zones. Each fold line is folded in the same direction at a consistent angle, simplifying the manufacturing process. The varying shape complexity is achieved through the arrangement and spacing of these standardized folds rather than varying the fold angles themselves.
Data Source
Figure 1A~1D
Figure 2A~4B
Figure 5A~7C
AI summary
A grate comprising at least one structural element (32, 33) made of at least a length of a reformed flat strip. The strip is folded successively along fold lines lying at an angle to a longitudinal axis of the unfolded strip. The strip comprises at least three fold lines extending parallel to each other, wherein at each fold line the parts are folded in the same direction. The strip comprises at least three flat parts (7, 8, 9), each part being connected to an adjacent part at one of the fold lines. The reformed flat strip forms a coil comprising a number of windings, wherein each winding comprises at least three flat parts.