Metal Grid Flap Laser Welding Hygiene
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Solution Overview
Problem
Existing grid flaps for filling devices and scales, particularly in food technology, face issues with adhesion, hygiene, durability, and production variability due to material limitations and design flaws, such as plastic abrasion, sharp edges, and manual production methods.
Innovation Solution
A metal grid flap with a welded wire mesh structure, where wire braces are arranged horizontally and vertically and interwoven, securely attached to a metal frame using laser welding, ensuring no loose ends or gaps, and featuring a sub-structure for enhanced strength and stability, allowing for machine-based series production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastic is used for the frame, then ease of manufacture is improved, but reliability deteriorates due to abrasion, fragility, and deformation under high temperature cleaning
Solution Approach 1:
The patent changes the material parameter from plastic to metal (specifically stainless steel), which fundamentally alters the properties: metal provides resistance to abrasion, high-temperature cleaning, and deformation, while maintaining manufacturability through standardized metal forming and welding processes
Solution Approach 2:
The patent employs metal (stainless steel) as the frame material, which can be considered a composite solution combining durability, hygiene resistance, and manufacturability. The metal material inherently provides the required mechanical strength and resistance to cleaning processes while allowing for precise fabrication
2Strength
If sheet metal plates with jammed grid are used, then strength is improved, but manufacturing precision deteriorates due to manual production and quality variability
Solution Approach 1:
The grid is segmented into individual wire braces that are separately formed and then systematically assembled and welded to the frame. This segmentation allows each component to be precisely manufactured and positioned, enabling machine-based assembly with consistent quality
Solution Approach 2:
The patent replaces manual mechanical assembly with automated welding processes. The wire braces are precisely positioned and welded to the frame using automated or semi-automated welding equipment, ensuring consistent manufacturing precision and eliminating hand-crafting variability
3Ease of operation
If wire netting is pushed into molten plastic, then ease of operation is improved for fixation, but harmful factors increase due to sharp edges and gaps that accumulate food residues
Solution Approach 1:
The patent extracts the wire netting from the plastic matrix concept and instead uses standalone wire braces that are welded directly to the metal frame. This eliminates the need for plastic encapsulation, removing the source of sharp edges and gaps while maintaining secure fixation through welding
Solution Approach 2:
The design uses simple, straightforward wire brace components that are easily replaceable if needed. The welded construction ensures durability without requiring complex retention mechanisms, and any damaged components can be readily replaced, maintaining hygiene standards
4Adaptability or versatility
If manual hand production is used, then adaptability is improved for custom designs, but productivity deteriorates due to individual crafting and quality variability
Solution Approach 1:
The grid flap is segmented into standardized components (frame and wire braces) that can be independently manufactured and then assembled. This modular approach enables machine-based production while maintaining design flexibility, as components can be easily adjusted or reconfigured for different applications
Solution Approach 2:
The patent creates a universal construction system using standardized metal frames and wire braces that can be adapted to various grid flap designs and applications. The modular welded construction serves multiple purposes: structural support, grid formation, and secure assembly, enabling both customization and efficient production
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
The solution provides a robust, hygienic, and reliable grid flap that prevents adhesion and residue accumulation, maintains structural integrity under stress, and enables efficient machine-based production, ensuring high product safety and consistency.
Implementation Method 1
Both can be fabricated from the same material. It is required in each case that the wire netting can be adhered to the frame by welding.
Data Source
AI summary
The invention relates to a grid flap (1) for use in a filling device or scale, especially in food processing, wherein the grid flap (1) comprises a metal frame (2) and a metal grid (4), and wherein the grid (4) comprises a plurality of braces (4h, 4v), which are connected to the frame (2) on their respective final sections.