Expanded Metal Element Folding With Edge Offset Preforming
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Solution Overview
Problem
Existing methods for expanding longitudinal, at least partially flat metal elements require significant force and can result in inaccurate kinks or misalignments, especially when producing thicker and stiffer metal profiles at high speeds, which are costly and inefficient.
Innovation Solution
The method involves offsetting the edge regions of the metal elements transversely before folding, using a press or rolling tool with a step feature to facilitate a favorable leverage effect, allowing for reduced force requirements and precise folding, and incorporating an embossing pattern for increased stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If edge regions are moved apart directly without offset to expand metal elements, then the expansion process is simpler, but the force required is excessive and folding precision is poor
Solution Approach 1:
The patent applies preliminary action by offsetting the edge regions before the actual folding operation. The cutting tool first creates offset positions for the edge regions, and only then are the regions moved apart and folded. This preliminary offsetting action prepares the metal element in advance, reducing the force needed during folding and improving precision without requiring complex equipment.
2Manufacturing precision
If traditional direct folding method is used, then the process is simpler, but folding precision and accuracy are poor
Solution Approach 1:
The cutting tool performs preliminary action by creating offset positions for the edge regions before folding. This preliminary cutting step establishes precise reference positions that guide the subsequent folding operation, ensuring accurate fold lines and consistent results without requiring complex folding machinery.
Solution Approach 2:
The offset cutting creates an intermediary structure between the original flat edge regions and the final folded configuration. This intermediary offsetted state serves as a transition phase that facilitates precise folding by providing defined hinge points and fold lines, acting as a mediator that improves precision without adding device complexity.
3Strength
If thicker and stiffer metal elements are expanded using traditional methods, then material strength is maintained, but force consumption increases significantly
Solution Approach 1:
For thicker and stiffer metal elements, the preliminary offsetting action is particularly effective. The cutting tool creates offset positions that pre-defin the folding geometry, allowing the material to be folded more easily despite its thickness and stiffness. This preliminary preparation reduces the force needed during the actual folding of strong, thick materials while maintaining their structural integrity.
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 expansion of thicker and stiffer metal elements with reduced force consumption and precise folding edges, avoiding inaccuracies and allowing for the production of wider metal profiles with reduced material and weight, while maintaining economic viability.
Implementation Method 1
using a press or rolling tool with a step feature to facilitate a favorable leverage effect, allowing for reduced force requirements and precise folding
Implementation Method 2
the connecting portions of the central area are folded together
Data Source
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AI summary
The invention relates to a method for expanding an elongated metal element (11) which is flat in at least some regions and each of which has two opposing edge regions (13) extending in the longitudinal direction (L) and an interposed central region (17) provided with cuts (15). The edge regions (13) are moved apart transversely to the longitudinal direction (L) and parallel to the areal extension of the metal element (11) such that central region (17) connection sections (19) which are formed by the cuts (15) and which connect the edge regions (13) together are folded. The edge regions (13) are offset relative to each other in a first method step before being moved apart transversely to the areal extension of the metal element (11) and are moved apart in the offset state in a subsequent second method step. The invention likewise relates to a device for expanding an elongated metal element (11) which is flat in at least some regions.