Segmented Supporting Core for Hollow Profile Forming
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Solution Overview
Problem
Existing supporting cores for forming structured hollow profiles face challenges in providing full-surface support for curved or variable cross-section profiles, as they often deform under forming forces and have limited bending capability, leading to incomplete shape retention and short lifespan due to wear.
Innovation Solution
A supporting core with interconnected, hinged members and coupling elements that allow partial formation of the inner contour, enabling full-surface support and flexibility to follow curved or variable shapes, with detachable connections and axial loading for enhanced resistance to forming forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rigid supporting core is used, then full-surface support is provided, but it cannot accommodate curved hollow profiles or variable cross-sections
Solution Approach 1:
The supporting core is divided into multiple individual supporting members that can be interconnected in a hinged manner. Each supporting member can be pulled apart and angled against others, allowing the core to adapt to curved hollow profiles and variable cross-sections while maintaining full-surface support capability when pushed together during forming.
2Manufacturing precision
If an elastomer supporting core is used, then full-surface support is provided, but forming forces cause deformation and wear
Solution Approach 1:
The elastomer supporting core is segmented into multiple individual supporting members connected by coupling elements. This segmentation allows each member to independently withstand forming forces without causing overall core deformation, while the coupling elements distribute mechanical stresses and reduce wear on individual components.
Solution Approach 2:
The supporting core combines elastomer material properties with a structured assembly of interconnected members. The elastomer provides full-surface support and flexibility, while the interconnected member structure enhances resistance to forming forces through distributed load bearing and hinged articulation.
3Ease of operation
If the supporting core is pulled after forming, then core removal is enabled, but the members must be kept apart in a certain distance
Solution Approach 1:
The supporting core uses segmented members connected by coupling elements with extensions and openings that enable form-fit connections. When pulled, the members can be easily separated and angled against each other, facilitating core removal while the simple extension-opening coupling mechanism minimizes overall device complexity.
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 solution allows for accurate and flexible production of structured hollow profiles with improved forming accuracy and simplified core removal, enabling efficient and economical manufacturing processes.
Implementation Method 1
the supporting members are interconnected in a hinged manner in the pulled-apart state
Implementation Method 2
the supporting members when being pushed together at least in part form as a surface the inner contour of the hollow profile to be produced
Implementation Method 3
the coupling elements of the supporting members comprise an extension with a form-fit area and an opening for the form-fitting accommodation of the extension and the form-fit area
Data Source
AI summary
A supporting core for using in a device for forming plates into a structured hollow profile and a method for producing structured hollow profiles from a plate, which on the one hand ensures an all-over support of the plate, and still enables the production of hollow profiles with a variable cross-section or a curved course, is provided by including individual supporting members, which when pushed together at least in part form as a surface an inner contour of the hollow profile to be produced and are interconnected by means of coupling elements, wherein the coupling elements allow the supporting members to be pulled-apart, and wherein the supporting members are interconnected in a hinged manner in the pulled-apart position.