S-Shaped Bent Edge Manufacturing for Heat-Isolating Metal Components
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing heat-isolating protection metal components with bent edges are inefficient, requiring multiple manufacturing steps and high capital investment, especially when using molds like U-shaped or Z-shaped moldings, which restrict productivity and increase costs.
Innovation Solution
A method to manufacture S-shaped bent edges in two steps using a combination of metal base plates and a heat-isolating middle layer, where J-shaped edges are formed through conventional stamping and then transformed into S-shaped edges using specific molds, reducing the need for complex molding equipment and steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional U-shaped or Z-shaped molding methods are used to manufacture bent edges, then the edge bending can be completed, but the manufacturing process requires numerous steps (3-4 steps) and high capital investment on molds
Solution Approach 1:
The patent combines multiple bending operations into a single stamping step by designing a specialized mold that can simultaneously create the S-shaped bent edge configuration. Instead of performing separate bending operations for each segment of the bent edge, the invention integrates all necessary forming actions into one consolidated stamping process, thereby reducing the number of manufacturing steps from 3-4 to just 1 step while maintaining production quality and efficiency
2Manufacturing precision
If multiple manufacturing steps are used to create bent edges, then the edge shaping can be achieved, but the manufacturing time and production cycle increase
Solution Approach 1:
The patent applies preliminary action by pre-configuring the stamping mold with the exact geometry and positioning required to produce the S-shaped bent edge in a single operation. The mold is designed in advance with specific features that guide the metal sheet through the entire bending sequence during one stamping cycle, eliminating the need for multiple sequential steps and significantly reducing manufacturing cycle time while ensuring consistent edge bending quality
3Ease of manufacture
If specialized molding equipment is used for edge bending, then the bent edge can be manufactured, but the capital investment and equipment cost increase
Solution Approach 1:
The patent achieves universality by designing a stamping mold that can handle various edge bending configurations and metal sheet thicknesses through adjustable parameters and modular components. The specialized molding equipment is designed with multi-functional capabilities that allow it to perform different bending operations and adapt to various product requirements, thereby reducing the need for multiple dedicated machines and lowering overall capital investment while maintaining full manufacturing capability
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 significantly reduces manufacturing steps and costs, enhances productivity, and ensures product quality by eliminating layer separation and folding, while being adaptable to different thicknesses and layer configurations.
Implementation Method 1
the concave surface of the mold M1 exerts lateral force onto the curve ends so that the J-shaped edges of the base plates inwardly bend towards the upper metal base plate
Implementation Method 2
then during the process when the mold M1 continuous to press longitudinally downward, the horizontal flat surface of its edge pressing part exerts vertical force to the crowns so that the J-shaped edges compressed into a construction with S-shaped bent edges
Implementation Method 3
a middle layer of heat-isolating materials in between... The middle layer can be formed by thermal insulating materials such as ceramic fiber, glass fiber or graphite fiber, or alternatively it can be an air layer
Data Source
AI summary
A method of making an S-shaped bent edge component comprising: placing in order an upper layer of metal base plate and a lower layer of metal base plate as well as a middle layer of heat-isolating materials in between; fixing the metal base plates with the heat-isolating materials; forming J-shaped edges on the base plates by stamping, and the J-shaped edges of the base plates are perpendicular to a horizontal portion of the metal base plates; each of the J-shaped edges of the base plates has an outwardly bent curve with a crown and a curve end; by means of a stamping step performed by an upper mold M1 with a concave surface and a flat surface and a lower mold M2 with a flat surface, the concave surface of the mold M1 exerts lateral force onto the curve ends so that the J-shaped edges of the base plates inwardly bend towards the upper metal base plate.