Trailer Coupling Holder Sheet Metal Forming

The patent applies hot forming and cold extrusion processes to transform sheet metal into a tubular body with specific geometric parameters. The hot forming process heats the sheet metal to increase plasticity, allowing complex three-dimensional shapes to be formed, while cold extrusion subsequently refines the geometry and increases surface hardness. This parameter transformation enables a simple sheet metal blank to become a structurally complex coupling holder with enhanced mechanical properties without requiring casting or forging.

The patent creates local quality variations through differential hardening. The cold extrusion process selectively hardens the outer surface of the tubular body where mechanical stress is highest, while the inner material remains more ductile. Additionally, specific regions like the holding receptacle and connection areas are reinforced through localized deformation contours. This local quality differentiation provides enhanced strength and wear resistance at critical areas without requiring the entire component to be made from high-strength forged material.

The patent merges multiple functions into the deformation and peripheral contours formed during manufacturing. The same hot forming and cold extrusion processes that create the tubular body's basic shape also simultaneously form the deformation contours (longitudinal ribs, circumferential ribs) and peripheral contours (holding receptacle, connection features). This integrated approach eliminates the need for separate post-processing operations to add reinforcement features, as all contours are formed in one continuous manufacturing sequence.

The patent performs preliminary action by pre-forming all necessary deformation contours and peripheral contours during the hot forming and cold extrusion processes before final assembly. The holding receptacle, connection features, and reinforcement ribs are all created as integral parts of the tubular body during forming, rather than requiring subsequent machining, welding, or attachment operations. This preliminary formation of all structural features simplifies the overall manufacturing process by eliminating secondary operations.

The patent applies the nesting principle by forming the form-fitting holding element as a nested feature within the tubular body itself. The deformation contours and peripheral contours create recesses and protrusions that are integral to the tubular structure. The holding element is not a separate component but is formed as part of the tubular body through controlled deformation during hot forming and cold extrusion, with harder material regions nested within the softer tubular matrix to provide positive locking surfaces.

The patent creates a composite structure within the tubular body by forming regions of different material properties through selective deformation. The cold extrusion process creates harder, more wear-resistant surfaces in specific regions where positive locking occurs, while the bulk material remains more ductile for energy absorption. This internal composite structure, with harder locking surfaces nested within softer structural material, provides reliable positive locking without requiring separate hardened components or complex assemblies.