Grid flap

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Solution Overview

Problem

Conventional lattice flaps in the food industry face issues with limited service life due to residual welding stresses, rigidity variations, and hygiene concerns related to complex geometries and substructures, which lead to adhesion problems and difficulty in cleaning.

Innovation Solution

A self-supporting lattice flap design with overlapping vertical and horizontal struts formed in one piece, eliminating the need for a substructure and allowing for various geometries, reducing stress and promoting a hygienic design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a wire mesh is welded to a metal frame using conventional methods, then the lattice flap can be manufactured, but residual welding stresses reduce the strength and service life

Engineering Contradiction:

Improvemanufacturability of lattice flapVSAvoidstrength at connection points

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent merges the frame and lattice into a single monolithic component manufactured by additive manufacturing, eliminating the welded connection between separate parts. This integration removes the interface where welding stresses would concentrate, thereby maintaining strength while enabling manufacture.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces the mechanical welding process with an additive manufacturing process that builds the frame and lattice as one continuous structure. This substitution eliminates the harmful thermal stresses and discontinuities inherent in welding while preserving the structural integrity and manufacturability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If individual wires are welded to the frame, then the lattice can be connected, but rigidity variations occur due to large cross-sectional changes

Engineering Contradiction:

Improveconnection of lattice to frameVSAvoidrigidity uniformity

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The frame and lattice are merged into a single continuously manufactured component, eliminating the abrupt cross-sectional changes that occur at welded joints. This ensures uniform rigidity throughout the structure while maintaining ease of manufacture through additive processes.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The additive manufacturing process enables local optimization of the lattice structure, allowing the cross-section to transition smoothly from the frame to the lattice wires. This gradual transition maintains consistent rigidity while accommodating the connection function.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If a wire mesh with individual wires is used, then flexibility is achieved, but the lattice lacks rigidity and requires additional substructure

Engineering Contradiction:

Improveflexibility of wire meshVSAvoidrigidity of lattice

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The patent combines the frame and lattice into a single monolithic structure, where the lattice wires are integrally connected to the frame. This integration provides the necessary rigidity while preserving the flexibility of the wire mesh configuration, eliminating the need for additional substructure.

Inventive Principle:

Principle #5Merging (Combining)

4Adaptability or versatility

If the lattice is made complex to achieve desired geometry, then design flexibility improves, but hygiene is compromised due to double surfaces and cavities

Engineering Contradiction:

Improvegeometric design flexibilityVSAvoidhygiene and cleanability

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The additive manufacturing process enables the creation of curved and complex geometries in the lattice structure that maintain hygiene. The process allows for optimized surface configurations that avoid sharp corners and hidden cavities, ensuring all surfaces are accessible for cleaning while achieving the desired geometric flexibility.

Inventive Principle:

Principle #14Spheroidality (Curvature)

5Ease of manufacture

If spot welding is used to connect wires, then the lattice can be assembled, but the wire cross-section is locally reduced and fatigue strength decreases

Engineering Contradiction:

Improveassembly of wire meshVSAvoidfatigue strength

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent replaces the spot welding assembly process with additive manufacturing, which builds the lattice wires and their connections to the frame as a continuous monolithic structure. This substitution eliminates the local cross-section reduction and stress concentrations caused by spot welding, thereby maintaining fatigue strength while enabling manufacture.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP3395697B1Grid flap

Publication Date: 2019.07.31 MULTIPOND WAGETECHNIK GMBH

Figure 1~2
Figure 3
Figure 4

AI summary

The present application is about a lattice flap (1), which has: a plurality of vertical (2v) and horizontal (2h) lattice struts, a frame (4) surrounding the lattice struts (2h, 2v), with a vertical one in each case (2v) and a horizontal (2h) lattice strut overlap at a crossing point (3), the crossing points (3) of the lattice struts (2h, 2v) being formed in one piece. Since the lattice is self-supporting due to its topology (in one piece) and two lattice struts do not lie one on top of the other, double surfaces or cavities can be dispensed with, which contributes to a hygienic design of the lattice flap.