Expanded Metal Element Folding with Pre-Displaced Margins
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Solution Overview
Problem
Existing methods for expanding elongated, at least regionally planar metal elements require high force and can result in inexact kinks, making it challenging to produce thicker and stiffer metal parts efficiently at high speeds with reduced material consumption.
Innovation Solution
Displacing the marginal regions transversely to the planar extent of the metal element before moving them apart, utilizing a pressing tool or rolling tool with a step to create a favorable lever effect and forming exact kink points, allowing for reduced force and precise folding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the marginal regions are moved apart directly without transverse displacement, then the folding process is simpler, but high force is required and inexact kinks occur
Solution Approach 1:
The patent applies preliminary action by performing a transverse displacement of the marginal regions before the main folding operation. The pressing tool with its step structure first displaces the marginal regions transversely to create pre-formed kink points, which then serve as accurate starting points for the subsequent folding process. This preliminary displacement ensures that the connection portions are properly positioned and oriented before the actual folding occurs, thereby achieving exact kinks while reducing the force needed during the final folding stage.
2Strength
If thicker and stiffer metal parts are processed, then product quality improves, but the force required for folding increases significantly
Solution Approach 1:
For thicker and stiffer metal parts, the preliminary transverse displacement becomes even more critical. The pressing tool's step structure creates initial kink points that break the stiffness resistance before the main folding force is applied. By pre-forming these kink points through transverse displacement, the metal part's structural resistance is reduced, allowing subsequent folding to proceed with acceptable force levels while maintaining the desired product quality and stiffness.
Solution Approach 2:
The patent introduces a transverse dimension to the folding process by displacing the marginal regions in a direction perpendicular to the plane of the metal element before folding. This dimensional change allows the connection portions to be drawn upward and form kink points in three-dimensional space, creating a favorable lever effect that reduces the force required for subsequent folding in the original plane. This approach enables processing of thicker, stiffer materials that would otherwise be too rigid for conventional planar folding.
3Loss of substance
If the metal element is expanded by folding connection portions, then material consumption is reduced, but the force required for folding increases
Solution Approach 1:
The transverse displacement performed before folding creates pre-formed kink points that reduce the resistance to folding. This preliminary action ensures that the connection portions are properly positioned and that the folding process encounters minimal structural resistance, thereby reducing the force required while maintaining the material-saving benefits of the folding expansion method.
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 the force required for folding, ensures accurate kink formation, and enables the production of thicker, stiffer metal parts with reduced material consumption and cost, facilitating high-speed manufacturing.
Implementation Method 1
utilizing a pressing tool or rolling tool with a step to create a favorable lever effect and forming exact kink points
Implementation Method 2
the marginal regions of the metal element are moved apart transversely to the longitudinal direction and in parallel with the planar extent of the metal element such that connection portions of the central region formed by the cuts and connecting the marginal regions to one another are folded
Data Source
AI summary
A method of expanding an elongated and at least regionally planar metal element that has two respective marginal regions oppositely disposed and extending in a longitudinal direction and a central region arranged therebetween and including cuts, the marginal regions of the metal element are moved apart transversely to the longitudinal direction and in parallel with a planar extent of the metal element such that connection portions of the central region formed by the cuts and connecting the two respective marginal regions to one another are folded, the method includes displacing the two respective marginal regions with respect to one another transversely to the planar extent of the metal element to form a displaced state, and subsequently moving apart the two respective marginal regions in the displaced state.