Reinforcing Plate Cross-Welding for Pressed Molded Products
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Solution Overview
Problem
The existing method of manufacturing molded products by overlaying and welding reinforcing plates on metal plates faces issues with positional offset and breakage due to increased hardness and reduced ductility from quenching, which can lead to decreased product quality and increased welding length.
Innovation Solution
The method involves welding two metal plates with intersecting welding beads to increase tensile strength without increasing welding length, reducing positional offset and breakage risks, and using techniques like laser or plasma welding to minimize strain and time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the welding length of the reinforcing plate is increased to reduce positional offset, then the positional offset decreases, but the hardness of the welded portion increases and ductility decreases, causing breakage during pressing
Solution Approach 1:
The patent transitions from a single linear welding direction to a two-dimensional crossed welding pattern. By performing welding in two different directions that intersect, the reinforcing plate is secured against positional offset in multiple dimensions without requiring excessive welding length in a single direction, thereby avoiding the quenching-induced brittleness that leads to breakage.
Solution Approach 2:
The welding process is divided into multiple segments with different welding directions. Instead of using a single continuous long weld, the patent segments the welding into multiple shorter welds performed in different directions, which reduces the cumulative heat input and prevents excessive hardening and brittleness in any single welded portion.
2Manufacturing precision
If the welding length of the reinforcing plate is increased to reduce positional offset, then the positional offset decreases, but the welding length increases
Solution Approach 1:
The patent employs welding in two different directions that cross each other, effectively utilizing two-dimensional space for welding. This approach provides comprehensive restraint against positional offset without requiring excessive welding length, as the crossed welds work together to secure the reinforcing plate in both directional dimensions.
3Productivity
If laser welding or plasma welding is used to reduce welding strain and time, then productivity increases, but manufacturing complexity increases
Solution Approach 1:
The patent replaces conventional arc welding methods with laser welding or plasma welding, utilizing optical or plasma fields instead of traditional mechanical/electrical welding systems. This substitution significantly reduces welding time and heat input, improving productivity while the crossed welding pattern helps manage the process complexity through systematic execution.
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 approach enhances the tensile strength of the welded area, reduces positional offset, and minimizes breakage during pressing, while maintaining the quality of the molded product without extending the welding length.
Implementation Method 1
the first welding and the second welding may be performed with laser welding or plasma welding
Implementation Method 2
the first welding and the second welding may be performed with laser welding or plasma welding
Implementation Method 3
hardness of the welded portion of the reinforcing plate increases by quenching performed during the welding
Data Source
AI summary
Provided is a method of manufacturing a molded product that can reduce problems on a reinforcing plate during pressing. In one aspect of the present disclosure, the method of manufacturing a molded product includes welding a first metal plate overlaid with a second metal plate to the second metal plate; and pressing the first metal plate and the second metal plate together. In the pressing, a base surface and a wall surface are formed on the first metal plate; the wall surface is disposed to cross the base surface. In the welding, a first welding is performed on a reinforcing portion of the second metal plate that is overlaid on an area of the first metal plate that is formed into the wall surface; and subsequently, a second welding is performed in a direction crossing a direction of the first welding.