Plate Joining Structure With Gap Relief for Stronger Metal Fastening
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Solution Overview
Problem
Existing plate member joining methods using the FDS method often result in gaps between joined metal plates due to excess metal being pushed out, leading to reduced joining strength and rigidity, as the plate thickness is compromised to minimize gap formation.
Innovation Solution
A plate member joining structure that incorporates a fitting base portion on the lower plate and a fitting insert portion on the upper plate, with a screw that screws into both, forming a gap to accommodate excess metal, thereby increasing the contact surface area and enhancing joining strength and rigidity, while maintaining plate thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the plate thickness is reduced at the joined portion to minimize gap formation, then the gap between plate members is suppressed, but the contact surface area between the screw and plate members is reduced, leading to reduced joining strength
Solution Approach 1:
The joined portion is segmented into three distinct regions: a first gap region that accommodates excess metal pushed out by the screw, a second gap region that prevents gap formation between plates, and a joined surface region that maintains full plate thickness for strong screw contact. This segmentation allows each region to serve its specific function without compromising overall joining strength.
Solution Approach 2:
Different regions of the joined portion have different local qualities: the first gap region has reduced plate thickness to accommodate excess metal, the second gap region maintains proper plate spacing to prevent gap formation, and the joined surface region maintains full plate thickness to ensure maximum contact area and joining strength. This local differentiation resolves the contradiction by applying thickness reduction only where necessary.
2Manufacturing precision
If the plate thickness is reduced at the joined portion to accommodate excess metal, then the excess metal can be contained without forming gaps, but the rigidity of the joined portion decreases
Solution Approach 1:
The joined portion is divided into regions with different thickness characteristics: the first gap region has reduced thickness for excess metal accommodation, while the joined surface region maintains full thickness to preserve rigidity. This segmentation allows the structure to accommodate excess metal without sacrificing overall rigidity.
Solution Approach 2:
The solution moves the thickness reduction from the overall plate structure to a specific localized dimension (the first gap region), while maintaining full thickness in the joined surface region. This dimensional differentiation allows excess metal accommodation without compromising the rigidity of the joined portion.
3Loss of substance
If a concave portion is provided at the lower surface of the lower plate to reduce plate thickness, then the amount of excess metal pushed out by the screw is reduced, but the contact surface area and joining strength are reduced
Solution Approach 1:
Instead of reducing plate thickness across the entire joined portion, the invention segments the structure to provide a concave portion (first gap region) only in the specific area where excess metal needs to be accommodated. The joined surface region maintains full plate thickness, ensuring maximum contact area and joining strength while still reducing excess metal formation in the concave region.
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 structure effectively suppresses gap formation between plates, improves joining strength, and increases the rigidity of the joined portion by accommodating excess metal within formed gaps, ensuring stable contact surfaces and enhanced load dispersion.
Implementation Method 1
a screw is press-fit in (screwed-in), while being rotated at a high speed, into a joined portion at which plate members that are made of metal are superposed vertically. The joined portion is welded by the heat of the friction with the screw
Data Source
AI summary
A plate member joining structure includes a lower plate that is made of metal, a fitting base portion being formed at an upper surface of the lower plate; an upper plate that is made of metal, that is disposed on the upper surface of the lower plate, and that has a fitting insert portion that is fitted to the fitting base portion so as to form a first gap between a lower surface of the fitting insert portion and a surface of the fitting base portion facing the lower surface of the fitting insert portion; and a screw that, in a state in which the fitting insert portion is fitted to the fitting base portion, is screwed into the fitting insert portion and the fitting base portion, and joins the fitting insert portion and the fitting base portion together in a plate thickness direction.