Cold-Formed Profile Element With Laser-Welded Connecting Sections
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Solution Overview
Problem
Existing thin-walled, cold-formed profile elements face challenges in cost and material efficiency due to material waste from punching processes, which hinders the production of wider profiles with maintained rigidity.
Innovation Solution
The method involves connecting longitudinal sections via an elongated, strip-shaped intermediate element, allowing for a wider profile formation without material loss, and using laser welding for enhanced strength and stiffness, along with transverse stiffening beads to reinforce the profile element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If openings are introduced by stamping process, then openings are formed in the profile body, but material waste increases manufacturing costs
Solution Approach 1:
The profile body is divided into two separate longitudinal sections that are formed without openings. The openings are created by the arrangement and connection of these sections, eliminating the need for material removal through stamping.
Solution Approach 2:
Connecting sections act as intermediaries between the two longitudinal sections. These connecting sections create the openings while maintaining structural integrity, and they are formed from the same material strip without waste.
2Area of stationary object
If profile width is increased, then more material is required, but material expenditure increases manufacturing cost
Solution Approach 1:
The profile body is segmented into two longitudinal sections that can be arranged side by side. This segmentation allows the profile to achieve greater width while using the same amount of material, as the sections are formed from a continuous strip without additional material consumption.
Solution Approach 2:
The profile width is increased by arranging longitudinal sections in the transverse direction rather than increasing the width of a single continuous section. This dimensional approach allows width expansion without proportional material increase.
3Shape
If openings are introduced by stamping, then openings are formed, but rigidity of the profile element decreases
Solution Approach 1:
The connecting sections are strategically positioned to provide local reinforcement in areas where openings are present. These connecting sections maintain rigidity by providing structural support at critical locations while still allowing openings to be formed in the profile body.
Solution Approach 2:
The profile body consists of multiple material sections (two longitudinal sections and connecting sections) that work together to maintain overall rigidity. The composite structure of these connected sections provides both the openings and the necessary structural strength.
4Area of stationary object
If two longitudinal sections are moved apart transversely, then wider profile is achieved, but connection between sections becomes more difficult
Solution Approach 1:
The connecting sections are pre-formed as integral parts of the longitudinal sections during the forming process. This preliminary formation of connecting sections simplifies the subsequent connection process, as the connecting features are already in place and ready for assembly.
Solution Approach 2:
The connecting sections serve as intermediaries that facilitate the connection between the two longitudinal sections. These connecting sections provide standardized connection interfaces that simplify the joining process, making it easier to connect sections that have been moved apart transversely.
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 approach enables the production of lightweight, cost-effective, and rigid profile elements with reduced material waste, maintaining or improving torsional and bending stiffness, and allowing for various applications without the drawbacks of conventional punching methods.
Implementation Method 1
using laser welding for enhanced strength and stiffness
Data Source
Figure 1~3
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AI summary
A thin-walled, cold-formed profile element, in particular a construction profile, such as a drywall, facade, plaster, screed, tile, or cable support profile, or a shelf or drainage rail, is described. The profile element has an elongated profile body, made primarily of metal or plastic, in which a plurality of openings are formed. The profile body comprises at least two separately formed longitudinal sections, each longitudinal section including a meandering longitudinal edge. Each longitudinal section comprises an elongated segment and a plurality of connecting segments projecting laterally beyond the elongated segment, which are bordered by the meandering longitudinal edge. Furthermore, a method for manufacturing such a profile element is described.