Expanded Metal Profiles with Radiused Edges
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Solution Overview
Problem
Existing metal profiles with longitudinally aligned holes for supporting plasterboard or forming shelves pose risks to users due to cutting edges, potential damage to cables, and cracking at hole ends, which compromise the profile's strength.
Innovation Solution
A method for producing expanded metal profiles involves unwinding a sheet metal strip, forming holes with bent edges, and then stretching it to create apertures with radiused edges and bosses, eliminating cutting edges and reducing cracking risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If holes are formed by transverse stretching of sheet metal strip, then productivity is improved, but cutting edges are created causing safety hazards and cable damage
Solution Approach 1:
The patent applies preliminary action by forming holes with bent edges before the final stretching operation. The bending rollers create initial hole forms with bent edges, and then the stretching rollers expand these pre-formed holes into the final apertures. This preliminary formation of holes with bent edges eliminates cutting edges while maintaining production efficiency.
2Ease of manufacture
If holes are formed by transverse stretching, then manufacturing simplicity is maintained, but cracking occurs at hole ends weakening the profile
Solution Approach 1:
The bending rollers perform a preliminary action by forming holes with bent edges before stretching. This pre-formed structure with bent edges prevents stress concentration at hole ends during the subsequent stretching operation, eliminating cracking while keeping the overall process simple and integrated.
3Device complexity
If holes with straight edges are used, then manufacturing complexity is reduced, but user safety is compromised due to cutting edges
Solution Approach 1:
The patent merges multiple functions into integrated roller assemblies. The bending rollers and stretching rollers are configured to work in sequence within a unified production line, combining hole formation with edge bending and aperture expansion in one continuous process. This integration maintains manufacturing simplicity while producing safe holes with bent edges.
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
The method enhances user safety by eliminating cutting edges, reduces cable friction, and strengthens the profile by preventing cracking, resulting in a safer and more durable product.
Implementation Method 1
pair of bending rollers (16) which, on the previously formed slits 12, 14, form longitudinally slotted holes 18, 20 with their edges bent towards the inside of the sheet metal strip
Implementation Method 2
pair of drawing rollers (22) having their punches shaped to curve the bent edges of the slotted holes to obtain a sort of radiused edging on each of said holes
Implementation Method 3
pair of stretching rollers (26) which exert transverse traction on the sheet metal strip to form apertures 28 at the holes 18, 20
Data Source
AI summary
A method for producing expanded metal profiles, consisting of subjecting a metal strip of width less than the development of the profile to be produced to the following operations: —forming longitudinal slits in at least that longitudinal band which is to form the central web of the profile, —bending the edges of the slits, —profiling said strip, —transversely stretching that band containing the slits, —pressing areas of said central web in correspondence with said stretched band to displace them external to the plane of said web, characterised by subjecting the bent edges to drawing to obtain radiused edging having the tangent to the free edge forming an angle not less than 90° to the surface of the strip.