Mesh Container Rim Forming Without Separate Welded Rails
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing mesh containers from expanded sheet metal are inefficient, leading to high manufacturing costs due to the need for separate welding and attachment of a rail at the rim, which complicates the process and increases costs.
Innovation Solution
A method involving perforating and expanding a web of sheet metal to form mesh material, where at least one portion remains unstretched to create precursors that are folded and bent to form side panels and a rim with a notch, allowing for a more rectangular cross-section and uniform rim formation, reducing material waste and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate welding and attachment of rail at rim is used, then container structure is formed, but manufacturing efficiency is low and costs are high
Solution Approach 1:
The patent combines the rim and side panels into a single integrated component formed from one continuous piece of expanded sheet metal. The rim is created by bending the metal at the corners rather than attaching separate rails through welding, merging multiple components into one that is formed, bent, and assembled as a unified structure.
Solution Approach 2:
The manufacturing process is segmented into distinct stages: forming the rim by bending at corners, cutting notches at specific locations, and assembling precursors. This segmentation allows each operation to be optimized independently while maintaining overall manufacturing efficiency.
2Ease of manufacture
If separate welding and attachment of rail at rim is used, then container structure is formed, but production costs are high
Solution Approach 1:
The patent eliminates the need for separate welding and attachment operations by integrating the rim formation into the main body of the container. The rim is formed by bending the expanded sheet metal at the corners, which removes the need for additional fasteners, welds, or attachment hardware, thereby reducing both material and labor costs.
Solution Approach 2:
The patent extracts the rim formation process from the separate welding and attachment operations. By taking out the rail attachment step entirely and replacing it with in-situ bending of the metal to form the rim, the process eliminates unnecessary complexity and reduces production costs.
3Ease of manufacture
If corner is formed with larger radius, then mesh material is easier to form, but container cross section is less rectangular
Solution Approach 1:
The patent applies preliminary action by forming the corner bends and notches while the metal is still in its expanded state, before final assembly. The notches are cut at specific locations to facilitate the bending process, allowing corners to be formed with tighter radii that achieve rectangular cross-sections while the material is more pliable.
Solution Approach 2:
The patent applies local quality by creating notches at specific corner locations where bending is required. These localized modifications allow the metal to be bent into tighter corners without compromising the overall structural integrity, enabling rectangular cross-sections while maintaining ease of formation at the critical corner regions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enhances manufacturing efficiency by forming containers from a single web of sheet metal, reducing material waste and simplifying assembly, resulting in lower production costs and a more uniform, functional container design.
Implementation Method 1
perforating and expanding a web of sheet metal along an expansion direction to form the mesh material
Implementation Method 2
That portion is bent to form a corner of the rim
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present disclosure relates to a mesh container and a method of making a mesh container. The container (28) has a first and a second set of opposing side panels (21, 23), a bottom panel (25), and a rim (27) directed outwards from the upper edges of the side panels (21, 23). The method involves perforating and expanding a web (7) of sheet metal along an expansion direction (3) to form the mesh material (1), while leaving at least one portion (13) of the web unstretched. At least one precursor (18, 20) is cut from the web. A container is folded including the at least one precursor making up, in one piece, at least a side panel in the first set (21) of side panels and a side panel in the second set (23) of side panels, which are joined by said unstretched portion (13) which is bent to form a corner (29) of the rim (27). A notch (33) is cut from the edge of the unstretched portion (13) where said corner of the rim is to be made.