Hollow Metal Bead Chains for Energy Absorbing Cellular Materials
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Solution Overview
Problem
Existing methods for manufacturing plastically deformable cellular materials based on hollow metal balls require the use of molds, limiting the ability to create hollow or recessed items and restricting the handling of hollow metal balls.
Innovation Solution
A method utilizing ball chains where hollow metal balls are connected by joints, allowing for easier handling and shaping of the material by winding around mandrels or intertwinning to form ball webs, which can be used to create items with complex shapes and provide high mechanical energy absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If hollow metal balls are used as elementary structures, then mechanical energy absorption capability is improved, but handling difficulty increases
Solution Approach 1:
The cellular material is segmented into modular hollow metal balls that can be independently handled and then assembled into chains. Each ball acts as an independent energy-absorbing unit with hollow interior that deforms plastically under impact, while the modular nature allows easy handling through chain assembly rather than manipulating individual loose balls.
Solution Approach 2:
Multiple hollow metal balls are merged into connected chains where adjacent balls are joined by joints. This combining approach maintains the energy absorption benefits of individual hollow balls while creating a unified structural element that is easier to handle, position, and install as a complete chain unit rather than managing numerous separate balls.
2Manufacturing precision
If molds are used to manufacture cellular material items, then manufacturing precision is improved, but adaptability worsens
Solution Approach 1:
The manufacturing approach transitions from static mold-based fabrication to a dynamic assembly process where ball chains can be flexibly arranged and configured. The chains maintain precision through controlled assembly operations while adapting to various target shapes by adjusting the arrangement, orientation, and configuration of individual chains during the building process.
Solution Approach 2:
The final item is segmented into multiple ball chain components that can be independently positioned and assembled. This segmentation allows the same standardized chain components to be configured into different item shapes and designs by varying the assembly pattern, thereby achieving shape adaptability without requiring different molds for each product variant.
3Ease of operation
If ball chains are used instead of loose balls, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The structure is segmented into standardized ball chain modules with consistent joint designs and ball configurations. This standardization reduces the complexity burden by creating repeatable units that simplify manufacturing, quality control, and assembly procedures, even though the chain structure itself is more complex than loose balls.
Solution Approach 2:
The ball chain design serves multiple functions simultaneously: it provides structural integrity through the connected ball-joint architecture, enables easy handling as a unified module, maintains energy absorption capabilities through hollow ball deformation, and allows flexible configuration into various item shapes. This multi-functionality justifies the increased structural complexity by delivering multiple benefits from a single design element.
Data Source
AI summary
Method, apparatus, and system for preparing a cellular material based on hollow metal beads. According to the description, at least one bead chain in which said hollow metal beads are linked to one another in pairs by means of an articulation is used as elementary structure constituting the cellular material.