Hollow Profile Reinforcement via Rotated Insert

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Solution Overview

Problem

Hollow profiles used in the automotive sector face challenges in achieving high rigidity and resistance to dynamic loads, particularly when subjected to transverse loading, as existing reinforcement methods either limit rigidity or increase weight and can negatively impact buckle formation during crashes.

Innovation Solution

A method for manufacturing hollow profiles by inserting a support element with a bolt element, engagement element, and support walls, which are rotated to touch the inner walls of the profile, allowing for a stable, materially integral connection that enhances dynamic rigidity and resistance to dynamic loads without significant weight increase or space requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If continuous cylindrical bushes are introduced into the hollow profile, then the hollow profile gains some rigidity, but the rigidity is limited particularly in transverse loading

Engineering Contradiction:

ImproverigidityVSAvoidresistance to dynamic loading

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The support element is segmented into a bolt element, engagement element, and support walls with longitudinal flanks, allowing it to be inserted through the hollow profile wall and rotated to engage with inner walls, providing enhanced rigidity and dynamic load resistance compared to continuous cylindrical bushes

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support element is pre-configured with longitudinal flanks that are designed to touch and connect to the inner walls of the hollow profile after rotation, creating a materially integral connection that provides immediate structural reinforcement upon installation

Inventive Principle:

Principle #10Preliminary action

2Strength

If external linkages are added to reinforce the hollow profile, then structural strength is improved, but weight increases significantly

Engineering Contradiction:

Improvestructural strengthVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The support element is nested within the hollow profile by inserting it through the wall and rotating it so that longitudinal flanks connect to inner walls, providing reinforcement from within the existing structure without adding external components that would increase weight

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The support element transitions from a linear insertion through rotation to a radial engagement configuration, where longitudinal flanks extend toward and connect with inner walls, utilizing the radial dimension of the hollow profile to distribute loads more effectively without adding external mass

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Strength

If external linkages are used for reinforcement, then some structural support is provided, but buckle formation during crashes is negatively influenced

Engineering Contradiction:

Improvestructural supportVSAvoidbuckle formation

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The support element provides localized reinforcement at specific points within the hollow profile where dynamic loads are applied, with support walls and longitudinal flanks creating targeted structural enhancement that maintains overall structural integrity and controlled buckle behavior during crashes

Inventive Principle:

Principle #3Local quality

4Strength

If support elements are inserted through the hollow profile wall, then rigidity is enhanced, but the insertion process becomes more complex

Engineering Contradiction:

Improvedynamic rigidityVSAvoidinsertion process

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The support element is pre-configured with a bolt element and engagement element that facilitate insertion through the hollow profile wall, with the engagement element allowing for controlled rotation and positioning once inserted, simplifying the overall manufacturing process despite the enhanced structural capability

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The engagement element acts as an intermediary between the insertion process and the final rotated position, providing a mechanism for controlled rotation and engagement with the inner walls without requiring complex external tooling or multi-step operations

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS10065388B2Method for manufacturing hollow profiles, and hollow profile

Publication Date: 2018.09.04 BENTELER AUTOMOBILTECHNIK GMBH

AI summary

The invention relates to a method for manufacturing hollow profiles, having the following method steps: providing an initial hollow profile which in an insertion wall and optionally in at least one intermediate wall displays an insertion opening, providing a support element which displays a bolt element, an engagement element, and support walls which are disposed between the bolt element and longitudinal flanks, passing through the support element through the insertion opening until the support walls are positioned in the initial hollow profile, engaging a tool on the engagement element, rotating the support element by means of the tool until regions of the longitudinal flanks touch inner walls of the initial hollow profile, connecting the regions of the longitudinal flanks to the initial hollow profile via the inner walls.