Segmented Sheet Metal Support via Laser Welding
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Solution Overview
Problem
Existing segmented carrier sheets for pads, such as fins, face challenges in cost-effectiveness and longevity, particularly under alternating stress, and offer limited design flexibility and stability.
Innovation Solution
A segmented carrier sheet comprising two segments connected via material-to-material connections, such as laser welding, with a corrugated design and adjustable geometry, allowing for almost unlimited part thicknesses and enhanced stability, and enabling unrestricted force-path characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connection methods are used for segmented carrier sheets, then production cost is reduced, but stability under alternating stress deteriorates
Solution Approach 1:
The patent replaces traditional mechanical connection methods (such as rivets, screws, or clips) with laser welding to join the segments. This substitution of the connection mechanism provides superior stability under alternating stress while maintaining cost-effectiveness through automated processing and elimination of additional fastening components.
2Adaptability or versatility
If fixed geometry designs are used, then manufacturing is simplified, but design flexibility and force-path characteristics are limited
Solution Approach 1:
The carrier sheet is divided into multiple segments that can be independently designed and manufactured with different geometries. This segmentation allows for optimized force-path characteristics in each segment while maintaining overall structural integrity through laser welding, enabling complex adaptive designs without proportionally increasing manufacturing complexity.
Solution Approach 2:
Different segments or regions of the carrier sheet can have different geometries, thicknesses, or material properties tailored to specific functional requirements. This local optimization enables customized force-path characteristics in different areas while keeping the overall design manageable through modular segmentation.
3Strength
If thin carrier sheets are used, then weight is reduced, but stability and load-bearing capacity deteriorate
Solution Approach 1:
The segmented design with laser-welded joints creates a composite structure where multiple thin segments work together to achieve the load-bearing capacity of a thicker monolithic sheet. The weld zones act as reinforcement points, and the segmented architecture can incorporate varying thicknesses or material properties to optimize strength-to-weight ratio.
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 solution results in a cost-effective, long-lasting carrier sheet with improved stability under alternating stress and flexible design options, simplifying production and enabling efficient assembly.
Implementation Method 1
the segments are connected to each other in a material-to-material fashion using laser welding
Data Source
AI summary
The invention relates to a segmented carrier sheet for at least one pad, such as a fin, comprising at least two segments.The invention is characterized in that the segments are connected to each other in a material-to-material fashion.