Tubular Connection Element Bending and Cutting Method
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Solution Overview
Problem
Existing corner elements for structures, whether made of metal or plastic, are either laborious to produce, prone to breakage, or lack sufficient structural resistance for large and heavy applications, making them unsuitable for commercial use in non-domestic settings.
Innovation Solution
A method involving a plastically deformable metal sheet is used to create a connection element by cutting and bending, forming orthogonal concave areas for tubular elements without welding, resulting in a robust and cost-effective corner element with enhanced structural resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If corner elements are produced by welding projections to bent metal sheets, then structural resistance is improved, but production complexity and time increase
Solution Approach 1:
The corner element is divided into multiple planar portions (first, second, third, fourth portions) that are bent along specific lines to form the final structure. This segmentation allows each portion to be independently formed and positioned, eliminating the need for welding while maintaining structural integrity through precise geometric configuration.
Solution Approach 2:
The invention transitions from a three-dimensional welded construction to a two-dimensional developed view that can be flat-patterned and then folded. By representing the corner element in its developed state with clear bending lines and cuts, the production process moves from complex spatial welding to simpler planar cutting and bending operations.
2Strength
If corner elements are produced by welding projections, then structural resistance is improved, but production time increases
Solution Approach 1:
The corner element is pre-formed with all necessary bends and cuts in its developed state before final assembly. The bending lines and cut lines are predetermined and marked on the flat sheet, allowing the element to be prepared in advance without requiring time-consuming welding operations during assembly.
Solution Approach 2:
The welding process is replaced with mechanical bending and cutting operations. Instead of using thermal or pressure welding to join projections, the invention uses mechanical force to bend the metal sheet along predetermined lines and make precise cuts, significantly reducing production time while maintaining structural strength.
3Ease of manufacture
If plastic material is used for corner elements, then ease of manufacture is improved, but structural resistance decreases
Solution Approach 1:
The invention changes the material parameter from plastic to metal (specifically aluminum or aluminum alloy), which fundamentally alters the mechanical properties. This parameter change enables the material to achieve the required structural resistance for heavy-duty applications while maintaining the ease of manufacture through simple cutting and bending operations.
Solution Approach 2:
The corner element utilizes aluminum or aluminum alloy, which can be considered a composite material system offering both lightweight properties and high strength-to-weight ratio. This material choice combines the ease of fabrication associated with lightweight materials with the structural resistance required for commercial and industrial applications.
4Strength
If welded corner elements are produced, then structural resistance is improved, but reliability decreases due to breakage at welded joints
Solution Approach 1:
The welding process and welded joints are completely extracted from the corner element construction. By removing the welding step entirely and replacing it with bending and cutting operations, the invention eliminates the weak points and potential failure sites that characterize welded joints, thereby significantly improving reliability and resistance to breakage.
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 method simplifies production, increases structural resistance, and eliminates weak points, making the connection element more robust and suitable for heavy-duty applications without the need for welding, thus overcoming the limitations of traditional methods.
Implementation Method 1
A method involving a plastically deformable metal sheet is used to create a connection element by cutting and bending
Data Source
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AI summary
The invention is a method for producing a connection element (1; 1') for tubular elements (2), comprising the following operations: bending a shaped laminar body (3; 3') along three converging bending lines (4, 5, 6) to define corresponding concave areas (7, 8, 9); making in the shaped laminar body (3; 3') two cuts (4a, 5a, 6a) mainly developed according to corresponding trajectories intersecting each corresponding bending line (4, 5, 6), so as to laterally delimiting corresponding strips (10, 11, 12) of material; lifting the strips (10, 11, 12) towards the inside of the corresponding concave areas (7, 8, 9), so as to define corresponding guide channels (13, 14, 15) developed parallel to the bending lines (4, 5, 6). The shaped laminar body (3; 3') is provided with two edge portions (21, 22) with corresponding shaped edges (21 a, 22a), one of which comprises a projection (23) suited to be fitted in a corresponding recess (24) belonging to the other shaped edge (21 a, 22a).