Planar Metal Element Aperture Folding for Stiffness and Material Savings
Solution Overview
Problem
Existing methods for producing apertures in areal metal elements, such as punching or expanded metal, result in material waste and reduced stiffness, making them uneconomic and less suitable for applications requiring high stability and material expansion.
Innovation Solution
The formation of apertures by folding over part sections in a one-piece metal element, avoiding expansion procedures that cause material strain, allowing for a significant widening of the material without waste and maintaining high stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If punching procedures are used to produce apertures in areal metal elements, then apertures are formed efficiently, but material is wasted and production costs increase
Solution Approach 1:
The metal element is divided into multiple part sections that can be independently folded. The central region includes at least two sections with outwardly disposed part sections that are folded over to form apertures, allowing the metal to be redistributed rather than wasted
Solution Approach 2:
The aperture formation transitions from a planar punching operation to a three-dimensional folding operation. By folding part sections over in the vertical dimension, apertures are created without removing material, as the folded sections form the aperture borders
2Loss of substance
If expanded metal is used to avoid material waste, then material is utilized efficiently, but strains arise in the material reducing stiffness
Solution Approach 1:
Instead of expanding the metal to create apertures (which causes strains), the invention inverts the approach by folding part sections to create apertures. This folding process does not subject the metal to the same tensile strains as expansion, preserving stiffness
Solution Approach 2:
The invention changes the geometric parameters of the metal element by folding part sections at specific angles. The outwardly disposed part sections are folded over to form aperture borders, creating a configuration that maintains material integrity while achieving the desired aperture structure
3Area of stationary object
If expanded metal is used to form apertures, then material widening is achieved, but the bending stiffness is reduced
Solution Approach 1:
The central region is segmented into multiple sections with outwardly disposed part sections that are folded over. This segmentation allows the metal to be redistributed to create apertures while maintaining structural continuity through the folded sections, preserving stiffness
Solution Approach 2:
The folded part sections create a composite structure where the original metal layout is combined with the folded-over sections. This composite configuration achieves both material widening through the folded geometry and maintains stiffness through the continuous metal flow and folding structure
4Productivity
If punching out part surfaces is done to form apertures, then apertures are created, but production costs are determined predominantly by material costs
Solution Approach 1:
Instead of discarding the punched-out material as waste, the invention recovers and utilizes all material. The part sections that would be discarded in punching are instead folded over to form the aperture borders, converting what would be waste into functional structural elements
Solution Approach 2:
The invention merges the aperture formation process with the structural element formation process. The same metal sections that form the aperture borders are also the structural elements themselves, eliminating the need for separate punching operations and reducing material waste
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 enables the production of metal elements with substantial material widening and high stiffness, reducing production costs and waste, while ensuring stability and permeability, suitable for various applications including plaster sections and composite materials.
Implementation Method 1
the outwardly disposed part sections are folded over with respect to the central part section to produce the aperture
Data Source
AI summary
An areal metal element is described having a surface which extends from a first outside edge to a second outside edge lying opposite the first out-side edge. The region of the metal element adjoining the first outside edge forms a first edge region and the region of the metal element adjoining the second outside edge forms a second side region. Both side regions are connected to one another by a central region lying therebetween, with at least one completely bordered aperture being formed at least in one of the side regions, with its border being formed in one part by this side region and in another part by the central region. The central region includes at least two sections which each consist of two outwardly disposed part sections and a central part section lying therebetween. The outwardly disposed part sections are folded over with respect to the central section to produce the aperture. The sections form part of the border of the aperture and the central region including the sections is made in one piece with the two side regions of the metal element.