Safe Deposit Box Housing Deep Drawing Without Welding
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Solution Overview
Problem
Existing safe deposit box manufacturing processes face challenges such as bending deviations, heat-induced deformation during welding, and a lack of integrated forming processes, resulting in poor quality, slow production, and a monotonous appearance.
Innovation Solution
An integrated forming process using cold-rolled steel sheets of a deep drawing grade to manufacture safe deposit box housings directly without welding, involving steps like blanking, drawing, shaping, trimming, embossing, outer door frame molding, frame cutting, and door frame flanging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional bending and welding processes are used to manufacture safe deposit box housings, then the manufacturing process is simple and familiar, but bending deviations occur, heat-induced deformation happens during welding, and the appearance becomes monotonous
Solution Approach 1:
The patent merges multiple separate manufacturing steps (blanking, bending, welding, polishing) into a single integrated deep drawing forming process. The housing is formed as one integral piece from a single steel sheet through coordinated drawing and shaping operations, eliminating the need for separate bending and welding steps while achieving precise geometric control through the forming tooling
Solution Approach 2:
The patent changes the material parameters by specifying deep drawing grade steel sheets with particular mechanical properties (yield strength, elongation) and thickness ranges. It also changes the process parameters by using cold forming instead of hot welding, controlling the forming pressure, temperature, and tooling geometry to achieve precise bending angles and complex shapes without heat-induced deformation
2Reliability
If thin steel sheets (within 2 mm) are used to reduce cost, then material cost decreases, but bending limitations occur and quality defects increase
Solution Approach 1:
The patent optimizes material parameters by selecting deep drawing grade steel sheets with specific mechanical properties: yield strength of 100-220 MPa, tensile strength of 250-350 MPa, and elongation of over 39%. The thickness is controlled within 0.7-1.5 mm. These parameter changes enable the thin sheets to be formed into complex three-dimensional shapes through deep drawing without cracking or deformation, achieving both cost reduction and high reliability
3Productivity
If multiple separate manufacturing steps are used, then flexibility in design is maintained, but production schedule slows down and costs increase
Solution Approach 1:
The patent combines multiple discrete manufacturing operations into one integrated deep drawing process. A single forming operation simultaneously creates the housing body, door frames, recesses, and mounting features that would otherwise require separate bending, welding, and assembly steps. This merging dramatically increases production speed while the tooling design maintains the necessary structural complexity
Solution Approach 2:
The forming process is segmented into distinct functional zones within the single deep drawing operation: blanking zone, drawing zone, shaping zone, and trimming zone. Each zone performs a specific function but all operate in sequence within one integrated tooling system, allowing complex geometry to be produced efficiently without multiple setup changes
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 integrated forming process enhances the quality and strength of safe deposit box housings, improves production efficiency, reduces costs, and allows for more complex and aesthetically pleasing designs.
Implementation Method 1
The cold-rolled steel sheets of the deep drawing grade and above are integrally formed to manufacture the safe deposit box housing directly without a step of welding
Data Source
AI summary
The invention belongs to the technical field of safe deposit boxes, and relates to a safe deposit box housing and an integrated forming method therefor. The integrated forming process comprises the following steps: blanking; drawing; shaping, trimming and shearing to obtain a housing blank; forming a groove in a front end plate of the housing blank by means of a door frame forming die, and forming an outer door frame by a part, other than the groove, of the front end plate; enabling an edge of the rest of the groove to extend towards a back surface in a direction perpendicular to the back surface by means of a door frame flanging die to form the flange, other than the flange, of the rest of the groove; and shaping the flange to obtain a safe deposit box housing.