Plate Assembly With Circular Arc Protrusions
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Solution Overview
Problem
Existing methods for joining metal plates, such as welding, brazing, and mechanical attachments, face issues like warping, high production costs, and the need for additional treatments, while existing mechanical connections suffer from reduced mechanical strength at varying protrusion distances.
Innovation Solution
A plate assembly featuring circular arced protrusions and indentations on both plate members, where the smallest indentation width matches the radius of the corresponding protrusion's circular arc, allowing for strong, easy, and cost-effective assembly without further treatment, and enabling waterproof joints through mechanical pressing or adhesive use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding process is used to join metal plates, then strong connection is achieved, but warping and deformation occur due to non-uniform heating and cooling
Solution Approach 1:
The patent replaces the thermal welding process with a mechanical joining system using protrusions and indentations. The protrusions on one plate mechanically engage with corresponding indentations on another plate, creating a strong connection without thermal input, thereby eliminating warping and deformation caused by non-uniform heating and cooling.
Solution Approach 2:
The patent employs circular arced protrusions and indentations instead of sharp or angular geometries. The curved surfaces distribute stresses more evenly during mechanical engagement, preventing stress concentration that could lead to deformation, while maintaining strong interlocking between plates.
2Strength
If welding process is used to join metal plates, then strong connection is achieved, but additional treatment and finishing are required
Solution Approach 1:
The mechanical protrusion-indentation system produces clean, precise joints without the rough surfaces and irregularities typical of welded joints. The molded or machined protrusions and indentations create smooth engagement surfaces that eliminate the need for post-weld grinding or finishing operations.
Solution Approach 2:
The protrusions and indentations are pre-formed on the plates through molding or machining before assembly. This preliminary creation of joining features ensures that when plates are connected, the mechanical engagement is immediate and requires no additional treatment, unlike welding which requires post-processing.
3Reliability
If mechanical fastening means such as brackets and screws are used, then attachment is achieved, but time-consuming assembly and sealing processes are required
Solution Approach 1:
The patent combines the attachment function and sealing function into a single integrated protrusion-indentation mechanism. The interlocking geometry itself creates the joint, eliminating the need for separate brackets, screws, and sealing operations, thereby dramatically reducing assembly time while maintaining reliability.
Solution Approach 2:
The patent extracts the essential joining function from complex multi-component fastening systems (brackets, screws, seals) and implements it through a simple, direct mechanical engagement of protrusions and indentations. This simplification removes unnecessary components and steps from the assembly process.
4Area of stationary object
If protrusions are spaced far apart, then coverage area is increased, but mechanical strength of engagement is reduced
Solution Approach 1:
The patent divides the connection interface into multiple discrete protrusion-indentation pairs distributed across the plate surface. Each pair acts as an independent load-bearing element, allowing the system to achieve both wide coverage through multiple distributed points and high strength through the cumulative effect of all engagement points working together.
Solution Approach 2:
The circular arced geometry of protrusions and indentations creates continuous surface contact during engagement, distributing loads evenly across the curved interface. This curvature allows each engagement point to maximize its load-bearing capacity while maintaining flexibility, enabling effective stress distribution even when protrusions are spaced to provide wide coverage.
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
A plate assembly (2) and a method for manufacturing such plate assembly (2) is disclosed. The plate assembly (2) comprises: - a first plate member (4) provided with a number of protrusions (10) and a number of indentations (12) arranged side by side; - a second plate member (6) provided with: a number of protrusions (14) and a number of indentations (16) arranged side by side, where the protrusions (14) are configured to be mechanically attached to a corresponding number of indentations (12) of the first plate member (4), where the indentations (16) are configured to be mechanically attached to a corresponding number of protrusions (10) of the first plate member (4). The indentations (12, 16) and the protrusions (10, 14) are circular arced, and that the circular arcs of the indentations (12, 16) are basically equal to the circular arcs of the protrusions (10, 14). The smallest width (t) of the indentations (12, 16) corresponds to the radius (r) of the circle corresponding to the circular arc of the protrusions (10, 14).