Space Frame Unitary Cell Design for Assembly Efficiency
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Solution Overview
Problem
Existing space frames do not include a three-dimensional unitary cell formed by bending a single piece of material to create both web and chord elements, which limits assembly efficiency and increases weight due to the need for heavy machined parts.
Innovation Solution
A space frame with a three-dimensional unitary cell formed from a single sheet of material, comprising continuous web elements that span nodes on multiple surfaces, with integrally formed chord elements that can be joined to form the structure, reducing the need for separate assembly of web and chord elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional separate assembly of web and chord elements is used, then manufacturing flexibility is maintained, but assembly complexity and weight increase
Solution Approach 1:
The patent merges web elements and chord elements into a single integrated three-dimensional unitary cell formed by bending a single piece of material. This integration eliminates the need for separate assembly operations between web and chord elements, directly reducing assembly complexity while maintaining manufacturing flexibility through the bending process.
Solution Approach 2:
The single piece of material serves multiple functions simultaneously: it forms both web elements and chord elements, and the same structure provides both structural support and structural continuity. This multi-functionality reduces the number of separate components needed, thereby simplifying assembly while preserving manufacturing adaptability.
2Strength
If heavy machined parts are used to connect web and chord elements, then structural strength is improved, but overall weight increases
Solution Approach 1:
By combining web and chord elements into a single continuous structure, the patent eliminates the need for separate connection parts (machined parts). The integrated design maintains structural strength through continuous material flow while avoiding the weight penalty of additional connection components.
Solution Approach 2:
The patent extracts and eliminates the heavy machined connection parts from the traditional assembly. Instead of using separate machined components to join web and chord elements, the design uses a continuous bent structure where the connection is inherent in the geometry itself, reducing weight while preserving strength.
3Productivity
If multiple separate components are used for web and chord elements, then manufacturing precision is maintained, but assembly time increases
Solution Approach 1:
The patent performs preliminary action by pre-bending the single piece of material into the complete three-dimensional unitary cell configuration before assembly. This pre-forming of the entire structure ensures geometric precision is achieved during manufacturing rather than during assembly, allowing for rapid installation while maintaining accuracy.
Solution Approach 2:
Merging web and chord elements into a single pre-formed unitary cell eliminates the time-consuming process of assembling multiple separate components. The integrated structure is ready for installation as a complete unit, significantly reducing assembly time while the bending process ensures manufacturing precision is maintained.
Data Source
AI summary
A space frame is provided having a first set of nodes located along a first surface and a second set of nodes located along a second surface, and a unitary cell. The second surface non-intersecting the first surface. The unitary cell comprises at least four continuous web elements and extending in three dimensions. The unitary cell spans at least two nodes of the first set of nodes and at least two nodes of the second set of nodes.