Laminated U-shaped Channel With Interlocking Features
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Solution Overview
Problem
Existing technologies face challenges in creating laminated channels with complex geometries and varying mechanical properties, particularly in achieving desired shear strength, bending strength, torsional stiffness, and flexibility, while allowing for clearance for additional components to travel along the length.
Innovation Solution
A laminated U-shaped channel is created by stamping and forming two components with interlocking locating features, allowing for varying materials and thicknesses, and attachment methods like welding or snap-fit, to form a passage for additional components, enabling alignment and mechanical property optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single solid channel structure is used, then structural integrity is achieved, but clearance for additional components to travel along the length cannot be provided
Solution Approach 1:
The channel is divided into multiple laminations (first lamination, second lamination, etc.) stacked together. Each lamination is a separate component that can be manufactured independently and then assembled, allowing the creation of internal passages and clearances while maintaining overall structural integrity through the layered construction.
Solution Approach 2:
Multiple laminations are nested or stacked within each other to form the final channel structure. The inner laminations create internal passages and clearances that allow additional components to travel along the length of the channel, while the outer laminations provide structural support and integrity.
2Shape
If complex geometries are created using traditional manufacturing methods, then desired shapes are achieved, but production cost and complexity increase
Solution Approach 1:
Complex channel geometries are segmented into multiple simpler lamination layers that can be manufactured using standard stamping and forming processes. Each lamination can be produced independently using conventional equipment, avoiding the need for expensive custom tooling or complex single-piece manufacturing processes.
Solution Approach 2:
Complex three-dimensional channel geometries are achieved by stacking multiple two-dimensional laminations. This approach transforms the manufacturing challenge from creating complex 3D shapes in a single operation to assembling simpler 2D layers, which can be produced more efficiently using standard sheet metal forming techniques.
3Ease of manufacture
If uniform material and thickness are used throughout the channel, then manufacturing simplicity is maintained, but optimized mechanical properties (shear strength, bending strength, torsional stiffness) cannot be achieved
Solution Approach 1:
Different laminations within the channel structure can have different materials, thicknesses, or material properties tailored to specific structural requirements. For example, certain laminations can be made thicker or from higher-strength materials in regions requiring enhanced shear strength, bending strength, or torsional stiffness, while other laminations use standard specifications.
Solution Approach 2:
The channel structure utilizes composite construction by combining multiple laminations that may be made from different materials or have different thicknesses. This allows the creation of a composite structure where the overall mechanical properties are optimized by selecting appropriate materials and thicknesses for each individual lamination layer.
Data Source
AI summary
A passage is formed between bases stamped, formed and laminated U-shaped channels. Interlocking locating features are formed into the inner and outer stamped and formed layers. Inner and outer components are attached by welds, glue, snap-fit or interference fit. Inner and outer components can be made of the same material and thickness or from different materials and thicknesses as needed to achieve the desired mechanical properties such as shear strength, bending strength, torsional stiffness or flexibility and longitudinal stiffness or flexibility. The materials may vary in thickness or composition along the length or height of the device to achieve the desired mechanical properties.