L-Shape Gliding End Piece Miter Joint Design
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Solution Overview
Problem
Existing methods for producing L-shaped sliding pieces from metal profile rails are complex, require excessive material, and result in visible seams or optical defects due to spot welding, which complicates the process and affects the aesthetic and structural integrity.
Innovation Solution
A method involving cutting a profile rail into sections with a triangular cut at the transition from horizontal to vertical sections, allowing the sections to be angled and permanently connected at the miter, eliminating visible seams and enabling secure assembly without additional post-processing, using techniques like spot welding or gluing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a large amount of material is used to punch out the L-shape from a rectangular profile rail, then the sliding piece can be formed, but excessive material is required and an open seam remains on the visible side
Solution Approach 1:
The profile rail is divided into two separate sections (horizontal and vertical) that are connected via a miter joint. This segmentation allows each section to be optimally sized without requiring excess material for punching, while the miter connection efficiently joins them with minimal material waste.
Solution Approach 2:
The solution transitions from a 2D punching approach (cutting L-shape from rectangular profile) to a 3D assembly approach (miter joint connection). By changing the dimensional strategy from planar cutting to spatial assembly, material usage is optimized and visible seams are eliminated.
2Strength
If spot welds are applied to secure the punched L-shape, then the shape is secured, but optical changes on the surface occur which are evaluated as material defects
Solution Approach 1:
The harmful spot welding process is extracted and replaced by a miter joint connection system. The connection functionality is maintained through mechanical interlocking and adhesive bonding, eliminating the harmful thermal effects and surface discoloration caused by spot welding while preserving structural integrity.
Solution Approach 2:
The thermal-mechanical spot welding process is replaced with a mechanical-adhesive connection system. The miter joint provides mechanical interlocking, while adhesive bonding provides the necessary strength without thermal effects, thereby eliminating surface defects and optical changes.
3Shape
If complex processing steps are used to form the sliding piece, then the L-shape can be produced, but the overall process becomes relatively complex
Solution Approach 1:
The profile rail is pre-cut to the exact length corresponding to the horizontal and vertical sections of the sliding piece before forming the miter joint. This preliminary dimensioning eliminates the need for subsequent material removal or complex forming operations, simplifying the overall process while ensuring precise L-shape geometry.
Data Source
Figure 1~2
Figure 3~7
AI summary
The production process involves using a strip rail bounded by the outer web (3a) of two webs (3a, 3b), separating off a triangular piece from the strip rail, forming a miter joint at the parting line, and joining the horizontal rear sector (5a) of the joint to the vertical front sector (5b) of the joint at a weld point (7) to fix it permanently.