Shear Bonding Device for Metal Plates
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Solution Overview
Problem
Conventional butt joint techniques for metal plates require trimming and are challenging for nonferrous or thick metal plates, and the melting methods used are difficult to apply, especially when bonding plates with different rigidities or thicknesses.
Innovation Solution
A shear bonding device and method that cuts and bonds metal plates by extruding pressure using perpendicular and slanted teeth, with heating clampers to achieve plastic flow and strengthen bonding, allowing for the cutting of front end portions in a hot solid state and bonding through extruding excess metal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional butt joint techniques with trimming and welding are used, then metal plates can be bonded, but the process requires multiple steps including trimming before bonding
Solution Approach 1:
The patent combines the trimming/cutting function and bonding function into a single integrated device. The shear bonding mold includes cutting edges that trim the metal plate edges while the bonding mold applies pressure to bond the plates simultaneously, eliminating the need for separate trimming and bonding operations.
Solution Approach 2:
The bonding device is divided into functional segments: the shear bonding mold for cutting/trimming, the bonding mold for applying pressure, and the heating clamper for thermal assistance. These segments work in coordinated sequence within a single operation cycle, allowing complex functions to be achieved through modular functional decomposition.
2Adaptability or versatility
If melting methods such as welding are used for butt joint, then metal plates can be bonded, but it is hard to apply to nonferrous metal plates or thick metal plates
Solution Approach 1:
The patent changes the bonding mechanism from thermal melting (welding) to solid-state bonding with plastic flow. By applying high pressure to induce plastic deformation and flow of the metal material at the bonding interface, the method achieves reliable bonding for diverse materials including nonferrous metals and thick plates without requiring melting, thereby expanding material compatibility while maintaining bond reliability.
Solution Approach 2:
The patent replaces the thermal/chemical bonding mechanism (welding/melting) with a mechanical bonding mechanism based on plastic flow and extrusion pressure. The bonding mold applies mechanical pressure to force metal plastic flow into the bonding interface, creating a mechanical interlock that is reliable across different metal types without relying on melting or chemical reactions.
3Manufacturing precision
If high pressure is applied to bond metal plates in conventional methods, then bonding can be achieved, but trimming process must be performed before bonding
Solution Approach 1:
The shear bonding mold performs preliminary trimming/cutting of the metal plate edges during the bonding process itself. The cutting edges of the shear bonding mold trim the plates to the required length and shape before the bonding mold applies bonding pressure, ensuring precise edge alignment is achieved as part of the bonding preparation rather than as a separate preliminary step.
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
Enables efficient bonding of metal plates with different properties by cutting and bonding in a single stage process, enhancing bonding strength through plastic flow and heat, suitable for various metal types and thicknesses, and reducing processing time compared to conventional methods.
Implementation Method 1
heating the bonding portions of the overlapped metal plates to become hot solid state by using upper and lower heating clampers
Implementation Method 2
agitating materials in the bonding portions through plastic flow and further strengthening bonding strength
Data Source
AI summary
A shear bonding device and a shear bonding method of metal plates are disclosed. The shear bonding device may include: an upper shear bonding mold having more than one upper perpendicular tooth and more than one upper slanted tooth formed alternately on a front end surface thereof; a lower shear bonding mold overlapped with the upper shear bonding mold in a vertical direction by a predetermined width below the upper shear bonding mold, and having more than one lower perpendicular tooth corresponding to the more than one upper slanted tooth and the more than one upper perpendicular tooth corresponding to the more than one lower slanted tooth formed alternately on a front end surface confronting the upper shear bonding mold; an upper heating clamper including a front end surface contacting with the upper perpendicular tooth of the upper shear bonding mold and adapted to generate heat by receiving power from a power supply; a lower heating clamper including a front end surface contacting with the lower perpendicular tooth of the lower shear bonding mold and adapted to generate heat by receiving power from the power supply; upper and lower pressing cylinders moving the upper and lower shear bonding molds upwardly or downwardly so as to apply load; and upper and lower clamping cylinders moving the upper and lower heating clampers upwardly or downwardly so as to apply clamping force and load, wherein the metal plates are disposed between the upper shear bonding mold and heating clamper, and the lower shear bonding mold and heating clamper.