Formed Extruded Profiles With Wave-Shaped Ribs for Vehicle Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Extruded profiles in commercial vehicle bodies require high manufacturing effort and have relatively low strength, limiting their applications and necessitating complex designs, which increases material usage and costs.
Innovation Solution
A method for producing formed extruded profiles involves heating metallic materials to a pressing temperature, pressing them through a die, cooling to less than 50°C, and then forming a rib structure that transitions from straight to wave-like in the longitudinal direction using alternating bending, allowing for strong and cost-effective profiles with complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If extruded profiles are used in commercial vehicle bodies, then weight savings are achieved, but strength is relatively low which limits application possibilities
Solution Approach 1:
The patent applies curvature by forming wave-like rib structures in the extruded profiles through alternate bending. This transforms straight ribs into curved/wave-shaped ribs that provide enhanced structural strength while maintaining the lightweight aluminum material, thus resolving the contradiction between weight savings and strength requirements.
2Shape
If post-processing of extruded profiles is necessary to achieve different cross-sections, then complex geometries are achieved, but manufacturing effort increases significantly
Solution Approach 1:
The patent performs preliminary forming of the rib structures during the extrusion process itself, rather than requiring separate post-processing steps. The alternate bending is integrated into the extrusion line, allowing complex cross-sectional geometries to be achieved without significantly increasing overall manufacturing effort.
Solution Approach 2:
The patent merges the extrusion process with the forming process by integrating the alternate bending step directly into the extrusion line. This combines what would traditionally be separate manufacturing operations into a single continuous process, reducing manufacturing effort while achieving complex geometries.
3Shape
If extruded profiles require post-processing to achieve different cross-sections, then complex geometries are achieved, but production time increases
Solution Approach 1:
The patent ensures continuity of useful action by integrating the alternate bending process directly into the extrusion line. The forming operation occurs continuously as the profile is being extruded, eliminating idle time between extrusion and forming operations, thus maintaining high productivity while achieving complex geometries.
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 simplifies production while maintaining high strength, reducing material usage, and enabling the use of extruded profiles in demanding applications like commercial vehicle bodies without increasing costs, providing a cost-effective solution with improved mechanical properties.
Implementation Method 1
a metallic material is heated to a pressing temperature
Implementation Method 2
the extruded profile is cooled to a temperature of less than 50 °C
Implementation Method 3
a rib structure extending rectilinearly in the longitudinal direction of the extruded profile is at least partially formed by alternate bending into a rib structure extending wave-shaped
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A method for producing a formed extruded profile (13) is described and illustrated. In order to simplify the manufacturing process without compromising the strength of the extruded profiles, the following procedure is used: a metallic material is heated to a pressing temperature and then extruded through a die to form an extruded profile (14); the extruded profile (14) is cooled to a temperature of less than 50 °C; and the extruded profile (14) is formed, at least section by section, less than 7 days after cooling.