Patent Publication Number: US-2019178269-A1

Title: Jointed metal plates and manufacturing method thereof

Description:
BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present invention relates generally to a method for manufacturing a metal plate product and the product thereof, in which multiple plates are jointed end-to-end. 
     Description of the Prior Art 
     Conventional end-to-end metal plate joints are mainly made by welding metal plates. The welded metal plates can be further polished to obtain a smooth jointed surface. Adequate mechanical strength can be achieved. 
     Nevertheless, there are insurmountable defects for welding technique due to its technical nature. The welding technique can be achieved by melting the edge of one or two jointing metal plates, solidifying the melted parts, and then connecting the plates. Alternatively, another metal can be melted and filled in the gap between two metal plates. No matter which way, melted metal parts are always necessary. In the melting process, metal melting is normally accompanied by high temperature and bright environment, both of which are likely to cause occupational injuries to on-site workers. Besides, high voltage or burning welding gas used for melting metal is also dangerous to the workers. When soldering is utilized, the workpiece will have protruding residual metal on its surface. Polish removal of the metal residuals can easily lead to metal dust, which will endanger the lungs of the workers. 
     SUMMARY OF THE INVENTION 
     One object of the present invention is to provide another way to connect metal plates end-to-end such that the welding techniques can be excluded with a view to improving the health and safety of workers. 
     To achieve the above and other objects, the present invention provides jointed metal plates including a first plate and a second plate. The first plate includes a first plate member and a plurality of protrusions. The first plate member has a first jointing edge. The protrusions are protruded from the first jointing edge in a jointing direction. The jointing direction coincides with an extension plane of the first plate member. The second plate includes a second plate member and a plurality of recesses. The second plate member has a second jointing edge from which the recesses are recessed in the jointing direction. 
     To achieve the above and other objects, the present invention provides a manufacturing method for jointed metal plates, which includes a plate cutting step, a stacking step and a stamping step. The plate cutting step is: cutting and obtaining a first plate and a second plate, in which the first plate includes a first plate member and a plurality of protrusions, the first plate member has a first jointing edge, the protrusions are protruded from the first jointing edge in a jointing direction, the jointing direction coincides with an extension plane of the first plate member, the second plate includes a second plate member and a plurality of recesses, the second plate member has a second jointing edge from which the recesses are recessed in the jointing direction. The stacking step is: stacking the first plate on the second plate in a manner that the protrusions abut against the second plate, each of the protrusions covering at least a part of one of the recesses when viewed in a direction perpendicular to the first plate. The stamping step is: after the stacking step, stamping the first plate and the second plate in a manner that the protrusions and the second plate are pressed and partially distorted and that the protrusions are embedded in the recesses respectively, thereby the first plate being fixed with respect to the second plate. 
     In view of the foregoing, the jointed metal plates and the manufacturing method thereof can connect multiple plates in an end-to-end manner without using welding techniques. Occupational injuries and work safety problems encountered during welding can thus be avoided. The production efficiency and the ease to control the manufacturing cost can also be achieved. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic view showing the state of use of the jointed metal plates according to the first embodiment of the present invention; 
         FIG. 2  is a perspective view of the jointed metal plates according to the first embodiment of the present invention; 
         FIG. 3  is a flow chart of the manufacturing method for the jointed metal plates according to the first embodiment of the present invention; 
         FIG. 4  is a partial plan view of the jointed metal plates according to the first embodiment of the present invention; 
         FIG. 5  is a partial profile of the first plate according to the first embodiment of the present invention; 
         FIG. 6  is a partial perspective view of the first plate according to the first embodiment of the present invention; 
         FIG. 7  is a partial perspective view of the second plate according to the first embodiment of the present invention; 
         FIGS. 8-13  are schematic views of the continuous processes of the manufacturing method of the jointed metal plates according to the first embodiment of the present invention; 
         FIG. 14  is a partial plan view of the jointed metal plates according to the second embodiment of the present invention; 
         FIG. 15  is a partial perspective view of the jointed metal plates according to the third embodiment of the present invention; 
         FIG. 16  is a profile taken along the line A-A in  FIG. 15 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The present embodiment provides a manufacturing method for jointed metal plates. Please refer to  FIG. 1 , the jointed metal plates may be assembled on the bottom of an adjustable desk or other devices for weighting or as a base. Please refer to  FIG. 2 , the jointed metal plates of the present embodiment includes a first plate  10 , a second plate  20 , a third plate  30  and a fourth plate  40  horizontally arranged on the same plane. Theses plates are substantially in rectangular shape, in which the second plate  20  is parallel to the third plate  30  while the first plate  10  and the fourth plate  40  both connect the second plate  20  with the third plate  30 . The first plate  10  to the fourth plate  40  as a whole constitutes the jointed metal plates. Four plates are used in the present embodiment and are used as a rectangular base, however other compositions are possible. For instance, a T-shaped base formed by two longitudinal jointing plates is possible. The jointed metal plates can be made by two or more plates. In the present embodiment, every adjacent plates are connected in the same method with similar structures. The first plate and the second plate are exemplary illustrated hereinafter. 
     Please refer to  FIG. 3 . The manufacturing method for the jointed metal plates according to the present embodiment includes a plate cutting step, a stacking step and a stamping step, in which an optional turning-over step can be further provided. 
     The plate cutting step is to cut and obtain the first plate  10  and the second plate  20 . Please refer to  FIGS. 2 and 4-6 . The first plate  10  includes a first plate member  11  and a plurality of protrusions  12 . The first plate member  11  has a first jointing edge  111 . The protrusions  12  are protruded from the first jointing edge  111  in a jointing direction respectively. The jointing direction is, for example, a direction coincides with an extension plane of the first plate member  11  and perpendicular to the first jointing edge  111  such that the protrusions  12  are respectively protruded in a direction away from the first plate member  11 . Each protrusion  12  may include a neck  121  and an engaging portion  122 , in which the neck  121  connects the engaging portion  122  to the first plate member  11 . The width of each engaging portion  122  is greater than that of its corresponding neck  121  in a width direction, which coincides with the extension plane of the first member  11  and perpendicular to the jointing direction. Thereby the first jointing edge  111  of the first plate member  11  in formed with, along the jointing direction, the protrusive narrow necks  121  and the wide engaging portions  122 . 
     Please refer to  FIGS. 2, 4 and 7 . The second plate  20  includes a second plate member  21  and a plurality of recesses  22 . The second plate member  21  has a second jointing edge  211  from which the recesses  22  are respectively recessed in the jointing direction. The second jointing edge  211  abuts against the first jointing edge  111  and therefore the jointing direction is also perpendicular to the second jointing edge  211 . Each recess  22  may include a throat portion  221  and a concave portion  222 , in which the throat portion  221  connects the concave portion  222  to the second jointing edge  211 . The width of each concave portion  222  is greater than that of its corresponding throat portion  221  in the width direction. That is to say, the second jointing edge  111  of the second plate member  21  is formed with, along the jointing direction, the recessed narrow throat portions  221  and the wide concave portions  222 . 
     The first plate  10  and the second plate  20  are metal plates, such as low-carbon steel plates. The first and the second plates can be obtained by die-cutting operations in which relatively larger plates are trimmed into the first plate  10  formed with protrusions and the second plate  20  formed with recesses. As shown in  FIG. 8 , the above-mentioned “die-cutting operations” means that the metal plate  50  is to be cut at a position borne on the edge of a die  60  by a punch  70  moving and punching the metal plate  50  in a cutting direction perpendicular to the metal plate  50  or the first plate. The metal plate  50  can be thus cut into the first plate or the second plate having a predetermined contour. Please refer to  FIGS. 6 and 7 . The upper surfaces of the first plate  10  and the second plate  20  are punch-in surfaces  13  and  23  where the punch  70  contacts, and the bottom surfaces thereof are punch-out surfaces  14  and  24 . The shear areas, especially the protrusions  12  and the recesses  22 , between the punch-in surfaces and the punch-out surfaces of the first plate  10  and the second plate  20  include a first side edge  15  and a second side edge  25  respectively. The first side edge  15  includes, sequentially from the punch-in surface  13  to the punch-out surface  14 , a first reference surface  151 , a first boundary line  152  and a first rupture surface  153 . The second side edge  25  includes, sequentially from the punch-in surface  23  to the punch-out surface  24 , a second reference surface  251 , a second boundary line  252  and a second rupture surface  253 . The first reference surface  151  and the second reference surface  251  are substantially perpendicular to the upper surfaces of the first plate  10  and the second plate  20  respectively. The first rupture surface  153  and the second rupture surface  253  are inclined to the first reference surface  151  and the second reference surface  251  respectively, in which an internal obtuse angle is formed between the first rupture surface  153  and the first reference surface  151 , and another internal obtuse angle is formed between the first rupture surface  153  and the punch-out surface  14 . There is also an internal obtuse angle formed between the second rupture surface  253  and the second reference surface  251 , while another internal obtuse angle is formed between the second rupture surface  253  and the punch-out surface  24 . 
     The first rupture surface  153  and the second rupture surface  253  are not necessarily flat, but the first rupture surface  153  and the second rupture surface  253  extend substantially obliquely from the first reference surface  151  and the second reference surface  251  respectively. Therefore the punch-out surfaces of the first plate and the second plate are slightly smaller than the punch-in surfaces thereof respectively. Please refer to  FIG. 5 , the first rupture surface  153  has an ending edge  154  away from the first reference surface  151 . The shortest distance between an extended plane of the first reference surface  151  and the ending edge  154  is 0.4-1 mm, preferably 0.6-0.8 mm. Similarly, the second rupture surface  253  has an ending edge  254  away from the second reference surface  251 . The shortest distance between an extended plane of the second reference surface  251  and the ending edge  254  is 0.4-1 mm, preferably 0.6-0.8 mm. 
     The turning-over step is to flip one of the first plate  10  and the second plate  20  by 180 degrees. For example, as shown in  FIG. 9 , the first plate  10  is turned 180 degrees, while the second plate  20  is not turned over. Thus the punch-in surface of the first plate  10  faces downward, and the punch-in surfaces of the first plate and the second plate face opposite directions. 
     Please refer to  FIGS. 10 and 11 . The stacking step is to stack the first plate  10  on the second plate  20  in a manner that the protrusions  12  abut against the second plate  20 . When viewed in the direction perpendicular to the first plate  10  as shown in  FIG. 4 , each protrusion  12  covers a portion or all of one of the recesses  22 . The dimensions of the first plate  10  and the second plate  20  are designed in the way that the maximum width of each protrusion  12  is greater than that of its corresponding recess  22 , while the difference between the maximum width of each protrusion  12  and that of its corresponding recess  22  is 0.8-2 mm, preferably 1.2-1.6 mm. Please refer to  FIGS. 10 and 11 . After the first plate  10  and the second plate  20  are stacked, the first rupture surface  153  faces and abuts against the second rupture surface  253  as shown in  FIG. 12 . The protrusions  12  bear against the periphery of the recesses  22  so that the first plate  10  and the second plate  20  cannot separate spontaneously and thus can be further processed. The protrusions  12  have a largest contour at the first reference surface  151  and a smallest contour at the ending edge  154 . The recesses  22  have a smallest contour at the second reference surface  252  and a largest contour at the ending edge  254 . To stably bear the protrusions  12  against the periphery of the recesses  22 , the smaller contour of the protrusions  12  need to be smaller than the largest contour of the recesses  22 . To prevent the protrusions  12  from directly falling into the recesses  22 , the largest contour of the protrusions  12  need to be larger than the smallest contour of the recesses  22 . 
     In the stamping step, the protrusions  12  and the recesses  22  are cooperated by a stamping operation in a manner that the protrusions  12  and the second plate  20  are pressed and partially distorted, and that the protrusions  12  are embedded in the recesses  22 . Thereby the first plate  10  is fixed with respect to the second plate  20 . The term “embedding” in the present invention refers to the situation that an object is substantially matched in shape with a space, but is different in size from the space, such that physical interference occurs between the object and another object formed with the space in a manner that the former object tightly fits and is accommodated in the space after the objects are pressed and deformed by an external force. Since the maximum width of each protrusion  12  is 0.8-2 mm larger than that of its corresponding recess  22 , the peripheral edges of the protrusions  12  and the recesses  22  deform rapidly and cooperate with each other in the stamping operation. Particularly, the first reference surface on the first side edge and the second reference surface on the second side edge deform in a manner that the protrusions  12  tightly embedded in the recesses  22 . Thus the first reference surface contacts the second rupture surface, while the second reference surface contacts the first rupture surface. However, as shown in  FIG. 13 , deformation surfaces  16  may be generated after the first side edge and the second side edge deform, in which the deformation surfaces  16  are obtained by partial deformation of the reference surfaces and the rupture surfaces. 
     As shown in  FIG. 2 , the first plate to the fourth plate can be obtained in the plate cutting step, in which both ends of the first plate and the fourth plate are formed with protrusions, while the second plate and the third plate are formed with recesses. The first plate and the fourth plate can be turned over in the turning-over step without turning the second plate and the third plate. Alternatively, the second plate and the third plate can be turned over in the turning-over step without turning the first plate and the fourth plate. In the stacking step, the first plate to the fourth plate are stacked. In the stamping step, the first plate to the fourth plate are stamped. The jointed metal plates constituted by the first plate to the fourth plate as shown in  FIG. 2  are thus obtained. 
     With the above manufacturing method, the jointed metal plates of the present embodiment can be made from several plates without welding processes. Labor injures and hazards during the welding processes, such as eye diseases caused by welding glare and safety concerns caused by welding gas, can be thus avoided. Additional processing required after the welding, such as the removal of welding residuals, can also be omitted. Processing costs and labor injuries can thus be reduced or mitigated. 
     In addition, the manufacturing method in the present embodiment utilizes only stamping press machines to complete the processes, which is simple and helps control the production cost. 
     Compared with the conventional welding processes, the stamping step in the present embodiment can process more plates at a time. The production efficiency can thus be increased while the cost can be lowered. 
     In some possible embodiment of the present invention, only one of the first side edge and the second side edge is formed with a rupture surface or is shaped otherwise. The turning-over step may be thus omitted from the method for manufacturing the jointed metal plates. 
     In the afore-mentioned embodiment, the contours of the protrusions and the recesses are substantially arc-shaped, however they can also be shaped otherwise. For instance, the embodiment as shown in  FIG. 14  discloses that the protrusions and the recesses can be changed into the trapezoidal shape Similar jointing effect to the prior embodiment can be obtained. 
     Please refer to  FIGS. 15 and 16  for the third embodiment of the present invention. The manufacturing method the jointed metal plates of the present embodiment is similar to that of the first embodiment. The jointed metal plates can be further pressed to form recessed notches  17  across the surfaces of the protrusions  12  and the second plate  20 . Such deformation helps the protrusions  12  fit more tightly with the recesses  22  to improve the jointing strength between the first plate  10  and the second plate  20 . The depth of the notches can be between 0.6-0.8 mm. 
     In view of the above, the manufacturing method for jointed metal plates provided by the present invention can replace the welding process by the stamping process during the end-to-end jointing of the metal plates, which not only reduces the occupational injuries of on-site workers but also helps control costs and increase production efficiency.