Notched Railing Grid Assembly With Plastic-Sealed Weld Joints
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Solution Overview
Problem
Existing methods for manufacturing barred grilles are costly, inflexible, and prone to corrosion, particularly in welding areas and contact points between bars and rails.
Innovation Solution
A method involving forming notches in rails or bars, positioning bars on rails at notch locations, welding the bars to the rails, and applying a plastic coating to fill residual spaces and enhance bonding and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If templates are used for positioning bars on rails, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent uses the rail itself as a template by forming notches directly on the rail surface. The notch serves as a physical copy or replica of the positioning feature, eliminating the need for separate external templates. This allows precise positioning of bars while avoiding the cost of manufacturing and maintaining separate template tools.
Solution Approach 2:
The rail performs the dual function of both structural component and positioning template. The notch formed on the rail automatically provides the positioning function, making the system self-sufficient without requiring additional positioning tools or fixtures.
2Manufacturing precision
If templates are used for positioning bars on rails, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The positioning function is extracted from a separate template tool and integrated directly into the rail structure through notches. This eliminates the need for distinct positioning devices and simplifies the overall manufacturing process.
Solution Approach 2:
The rail combines multiple functions: it serves as both the structural support element and the positioning template. The notch on the rail integrates the positioning feature directly into the rail, reducing the number of separate components and steps required.
3Reliability
If galvanizing treatment is applied to the grid, then corrosion resistance is improved, but welding areas still show corrosion traces
Solution Approach 1:
The notches are formed on the rails before welding the bars. This preliminary action creates precise positioning features that reduce welding residual spaces and improve weld quality, thereby enhancing corrosion resistance at critical welding areas even after galvanizing treatment.
4Ease of manufacture
If bars are embedded in notches and fixed by locking rod, then assembly is simplified, but manufacturing precision requirements increase
Solution Approach 1:
The notch on the rail serves as a precise physical copy of the bar's positioning requirement. By forming the notch directly on the rail, the positioning geometry is replicated accurately, ensuring precise fit without requiring high-precision manual fitting 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 method reduces manufacturing costs, allows for customized grid designs, improves the strength and durability of the grilles by enhancing the bond between bars and rails, and provides better corrosion resistance and aesthetics.
Implementation Method 1
plasticizing the barred grid with a plastic coating so as to cover the rails and the bars and to fill the residual spaces between said bars and said rails at the level of the notches
Implementation Method 2
welding said bars to said rails so as to form said barred grid
Data Source
Figure 1
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AI summary
A method for manufacturing a barred grid (1, 1', 1") from at least two rails (2, 2', 2") and a plurality of bars (3, 3', 3"), comprising the following successive steps: - forming notches (4, 4', 4") in said at least two rails (2, 2') or said bars (3"); - positioning said bars (3, 3', 3") on said rails (2, 2', 2") at the location of said notches (4, 4', 4"); - welding of said bars (3, 3', 3") to said rails (2, 2', 2") so as to form said barred grid (1, 1', 1"), and - plastic coating of said barred grid (1, 1', 1") so as to cover the rails (2, 2', 2") and the bars (3, 3', 3") with a plastic coating and to fill the residual spaces between said bars (3, 3', 3") and said rails (2, 2', 2") at the level of said notches (4, 4', 4").