Cold Extruded T-Shaped Lock Retainer for Motor Vehicle
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Solution Overview
Problem
Existing lock holders for motor vehicle locks require complex manufacturing processes and post-processing, leading to increased costs and effort, with a complex structure that often necessitates additional installation steps for secure operation.
Innovation Solution
A method involving cold extrusion to form a T-shaped lock holder from a round raw material, eliminating the need for post-processing by creating the retaining bores and recesses in a multi-stage manufacturing process, allowing for a one-piece, stable lock holder with optimized geometry and material distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If lock holders are produced by cold forming or stamping and punching, then manufacturing cost is reduced, but post-processing is still required and structure becomes complex
Solution Approach 1:
The patent combines multiple previously separate components (retaining bolt, lock shackle, base plate) into a single integrated lock holder produced by cold extrusion. This merging eliminates the need for separate retaining bolts and brackets, simplifying the overall structure while maintaining functionality. The integrated design allows the lock holder to be produced as one piece without requiring post-assembly operations.
Solution Approach 2:
The manufacturing process is segmented into distinct cold extrusion stages that form different portions of the lock holder sequentially. The process first forms the base plate, then the lock shackle with shackle legs, and finally integrates these into the complete lock holder structure. This segmentation allows complex geometry to be achieved through systematic forming steps rather than requiring complex single-step operations.
2Ease of manufacture
If lock holders are produced in two parts with separate retaining bolts, then manufacturing is simpler, but additional post-processing and installation steps are required
Solution Approach 1:
The cold extrusion process performs preliminary forming of the complete lock holder geometry including the base plate, lock shackle, and shackle legs in a single integrated operation. The retaining bores and recesses are pre-formed during the extrusion process itself, eliminating the need for subsequent post-processing steps such as drilling, punching, or assembling separate retaining bolts. This preliminary action ensures all features are ready for immediate installation.
3Reliability
If complex pressing processes are used to produce lock holders in one piece, then post-processing is eliminated, but manufacturing effort and cost increase
Solution Approach 1:
The patent employs cold extrusion parameters (temperature, pressure, deformation rate) that enable the formation of complex lock holder geometry without requiring excessively complex pressing equipment or multi-step processes. By optimizing the extrusion parameters and using appropriate tooling, the process achieves high-quality one-piece production with standard manufacturing capabilities, balancing reliability with manufacturing efficiency.
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 reduces manufacturing costs and time by eliminating post-processing steps, enhancing mechanical resilience, and ensuring the lock holder can be directly integrated into motor vehicle locks without additional processing, while maintaining high-quality surface finish and load capacity.
Implementation Method 1
the lock holder is formed by cold extrusion from a preferably round raw material by massive forming into a T-shaped semi-finished product
Implementation Method 2
The material is made to flow under the influence of high pressure, with temperatures of up to around 900 °C in the object, which lead to a deformation that makes any post-processing superfluous
Implementation Method 3
the retaining bores and the recess in the lock shackle are then formed from the high cold-upsetting quality present semi-finished product
Data Source
Figure 1
Figure 2~3
AI summary
In order to produce a lock retainer (1) for locks, preferably motor vehicle locks, a rod-shaped raw material made of steel is first solidly shaped into the lock retainer (1) by means of cold extrusion in a plurality of sub-steps, wherein during said solid shaping process the final shape of the lock retainer (1) is produced in such a way that further processing steps can be omitted. The only remaining step then is to remove the opening (10) from the accordingly designed or shaped lock bow having the bow legs (5, 8) and to remove the retaining holes (3, 4) from the base plate (2) by means of punching or laser cutting or a similar process. The lock retainer (1) produced by means of such a method is characterized by a clear and smooth overall geometry, a surface structure (20') being applied and optionally material being accumulated in the severely loaded areas and thus overall a lock retainer (1) not requiring further post-work being available after the sub-steps of the cold extrusion.