New joining of aluminum profiles through targeted folding

Abstract

Aluminum profile joining unit, consisting of at least two aluminum profiles, characterized in that at least one aluminum profile is locally folded in defined desired fold zones in order to produce a positive and non-positive connection with another aluminum profile, wherein the connection is carried out without additional mechanical or thermal joining technology.

Description

[0001] Description of the joining principle by folding adjacent aluminum profiles. The described technical connection is based on the principle of local plastic deformation of aluminum profiles, whereby two adjacent profiles are joined together in a form-fitting and force-fitting manner by targeted folding. This creates defined contact areas (zones) between the profiles. These zones are geometrically designed (e.g., through local wall thickness reduction, cross-sectional modification, or material cutouts) so that they buckle or fold in a controlled manner under the influence of a targeted force absorption without damaging the remaining profile. Joining process:Positioning:

[0002] Two extruded aluminum profiles are placed side by side in a fixture so that their respective folding areas lie against each other or slightly overlap ( Fig. 1). Lateral guides (A) are positioned in the device to ensure that the sheets fold together. Requirement:

[0003] Both profiles contain the necessary chemical components and have not undergone any required processes during production. The profiles have a T7xx heat treatment condition. Folding process:

[0004] Using a forming tool or mechanical force application (e.g., presses, rollers, or active folding units), the profiles are forced to fold. The folds fold into the indentation of the other profile. This creates a mechanical wrap or clamp, which enables a permanent connection ( Fig. 2). Backup:

[0005] Optionally, the connection can be reinforced with additional elements such as positive locking lugs, barbs or friction surfaces. Advantages of this procedure:

[0006] No welding, gluing or drilling necessary → material-friendly and cost-effective Fully reversible or non-destructively separable, if desired Suitable for automated processes in series production High mechanical strength, especially in crash-relevant applications Typical applications:

[0007] Modular structures in vehicle construction (e.g. crash absorbers), frame connections in lightweight construction, energy absorbers with defined deformation behavior, structural composites made of multi-chamber profiles

Claims

[1] Aluminium profile joining unit, consisting of at least two aluminium profiles, characterized by that at least one aluminum profile is locally folded in defined desired fold zones in order to create a positive and non-positive connection with another aluminum profile, wherein the connection is carried out without additional mechanical or thermal joining technology. [2] Aluminium profile joining unit according to claim 1, characterized by that the desired fold zones are provided by a targeted change in the geometry of the cross-section of the aluminum profile, in particular by local material constriction or wall thickness reduction in the manufacturing process of the profile. [3] Aluminium profile joining unit according to one of claims 1 or 2, characterized by that the folding is designed in such a way that after joining, the connection is mechanically self-locking. [4] Aluminium profile joining unit according to one of claims 1 to 3, characterized bythat the folded profiles have an additional function for energy absorption in the event of axial or lateral loads. [5] Aluminium profile joining unit according to one of claims 1 to 4, characterized by that the aluminum profiles consist of an alloy group EN AW-5xxx, 6xxx and 7xxx and have specifically adapted mechanical properties in the folding area. [6] Use of the aluminum profile joining unit according to one of claims 1 to 5 for the production of structural components in vehicle construction, aerospace construction, rail vehicle construction or mechanical engineering.

Images