Stretched-Aperture Building Profiles for Low-Waste Manufacturing
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Solution Overview
Problem
Current building profiles require resource-intensive and energy-consuming processes to create material apertures, leading to material waste and increased production costs, which negatively impact the environmental sustainability of their manufacturing.
Innovation Solution
The production of building profiles involves creating through cuts in a raw strip using a cutting process like rotary cutting or laser cutting, followed by a stretching process that widens these cuts into material apertures without material loss, eliminating the need for additional processing steps and reducing resource and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If material apertures are created by working out material to produce lumpy pieces or chips, then the apertures are formed successfully, but material waste is generated and processing costs increase
Solution Approach 1:
The invention changes the physical state and dimensions of the aperture by stretching the through-cut in the longitudinal direction. This transforms the aperture from a small cut into an elongated opening, achieving the desired aperture form without generating material waste. The stretching process modifies the geometric parameters of the aperture while maintaining material integrity.
Solution Approach 2:
The invention replaces traditional mechanical aperture creation methods (which involve removing material through punching, drilling, or milling) with a stretching process. This substitution eliminates the generation of material chips or lumpy waste, as the aperture is formed by elongating the material structure rather than removing material.
2Ease of repair
If separate process routes are provided for processing material waste, then material can be reused, but production costs and resource consumption increase
Solution Approach 1:
The invention extracts the harmful element (material waste) from the production process by eliminating its generation in the first place. Through the stretching process, no material waste is produced, so no separate waste processing routes or equipment are needed. The solution removes the problem at its source rather than dealing with it downstream.
Solution Approach 2:
The stretching process is self-sufficient in that it directly produces the desired aperture form without generating waste that would require additional processing. The process serves its own purpose of creating functional apertures without creating byproducts that need separate handling, thus eliminating the need for additional processing equipment.
3Manufacturing precision
If traditional aperture creation methods are used, then apertures are formed, but energy consumption and production costs increase
Solution Approach 1:
The invention changes the approach to aperture creation from material removal to material deformation. By stretching the through-cut in the longitudinal direction, the process achieves aperture formation with lower energy consumption, as it avoids the high-energy operations associated with cutting, punching, or milling away material.
Solution Approach 2:
The invention replaces energy-intensive mechanical removal processes with a stretching process that deforms the material in place. This substitution significantly reduces energy consumption by eliminating the need for high-force cutting operations and subsequent waste handling processes.
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
This method allows for the production of building profiles with reduced material waste and lower resource and energy usage, improving the environmental sustainability of the manufacturing process while maintaining the anchoring functionality of material apertures.
Implementation Method 1
a stretching device by means of which a profiled strip is produced from the precursor strip by widening the through cuts in the longitudinal direction to the material apertures
Data Source
AI summary
A building profile having a first and a second strip-shaped profile leg and a connecting section which connects the first profile leg and the second profile leg in the longitudinal direction, wherein the profile legs form a profile angle. At least one of the profile legs has material apertures which are produced from through cuts by a stretching process. A method for manufacturing such a building profile; an installation for manufacturing a profiled strip comprising material apertures which forms a building profile precursor from which said building profiles are produced; an installation for manufacturing such a building profile from a profiled strip comprising material apertures which are produced from through cuts a stretching process; an apparatus for manufacturing such a building profile from a raw strip; and the use of an installation in the production of building profiles, in the form of angle profiles for protecting wall edges or corners or in the form of quick-plastering profiles or in the form of support rails or stand profiles, in the production of building profiles mentioned at the outset.