Interlocking Metal Plate Joint for Spring-Back-Resistant Tubes
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Solution Overview
Problem
Conventional methods for manufacturing tubular bodies from metal plates face issues such as joint instability due to spring back, increased workability concerns, and precision and adhesion deterioration when combining multiple plates, leading to potential buckling and reduced fitting accuracy.
Innovation Solution
A metal plate configuration where one end surface features a recessed portion with an engaging portion, and the opposing end surface has a protruding portion that is bent to hook into the recessed portion, ensuring stable adhesion by maintaining the length of the protruding portion within the depth of the recessed portion, thereby preventing buckling and enhancing engagement accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a metal plate is bent to form a tubular body, then the tubular shape is achieved, but the joint opens due to spring back
Solution Approach 1:
The metal plate is divided into multiple plates (first metal plate and second metal plate) that are joined together to form the tubular body. This segmentation allows for separate processing of each plate and provides multiple joining points, improving joint stability while maintaining the tubular shape.
Solution Approach 2:
Protruding portions and recessed portions are formed on the metal plates before the joining process. These pre-formed features prepare the plates for accurate alignment and secure engagement, preventing joint opening due to spring back during the bending and joining operations.
2Shape
If two metal plates are combined to form a tubular body, then the tubular shape is achieved, but workability deteriorates as the number of processing steps increases
Solution Approach 1:
The metal plate is divided into multiple plates (first metal plate and second metal plate) that are joined together to form the tubular body. This segmentation allows for separate processing of each plate and provides multiple joining points, improving joint stability while maintaining the tubular shape.
Solution Approach 2:
Protruding portions and recessed portions are formed on the metal plates before the joining process. These pre-formed features prepare the plates for accurate alignment and secure engagement, preventing joint opening due to spring back during the bending and joining operations.
3Shape
If two metal plates are combined with protruded and recessed portions, then the tubular shape is achieved, but the portion is likely to buckle when combined or caulked
Solution Approach 1:
The protruding portions and recessed portions are designed with specific dimensional relationships (protrusion length less than recess depth) to provide localized engagement zones. This local quality enhancement ensures precise fitting at the joining portions while preventing buckling during the combining and caulking processes.
4Shape
If two metal plates are combined, then the tubular shape is achieved, but the adhesiveness of the metal plates at the joint deteriorates
Solution Approach 1:
The metal plate is divided into multiple plates (first metal plate and second metal plate) that are joined together to form the tubular body. This segmentation allows for separate processing of each plate and provides multiple joining points, improving joint stability while maintaining the tubular shape.
Solution Approach 2:
Protruding portions and recessed portions are formed on the metal plates before the joining process. These pre-formed features prepare the plates for accurate alignment and secure engagement, preventing joint opening due to spring back during the bending and joining operations.
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 configuration allows for stable adhesion between the end portions of a single metal plate, resisting spring back and maintaining precision in the tubular body's joint, thereby improving the manufacturing process and product reliability.
Implementation Method 1
applying a bending process such that the engaging portion is hooked by the protruding portion
Implementation Method 2
the joint of the metal plate may open due to the spring back
Data Source
AI summary
A metal plate includes: a recessed portion provided at one end surface by cutting out the metal plate in a planar direction of the metal plate, the recessed portion having an engaging portion inside the recessed portion; and a protruding portion provided at a position on another end surface, the position corresponding to that of the recessed portion, the protruding portion protruding in the planar direction, the protruding portion being engaged with the engaging portion by applying a bending process such that the engaging portion is hooked by the protruding portion, wherein a length from a proximal end portion to a distal end portion of the protruding portion before the bending process is applied is equal to or less than a depth of the recessed portion at a position of the recessed portion, the position facing an end surface of the proximal end portion of the protruding portion.