Trailer Coupling Profile Body Segmentation for Weight Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing carrier arrangements for trailer hitches and load carriers are expensive and heavy due to the need for custom-made side supports to adapt to different vehicle contours, and there is a requirement for a lighter design.
Innovation Solution
The carrier arrangement connects adjacent profile segments using a common peripheral wall and retaining projections, allowing for a material-saving production method where segments are cut and joined at miter angles, creating a resilient profile body with a curved or angled course, and utilizing hook-like connections for high-tensile strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If custom-made side supports are produced to adapt to different vehicle contours, then the carrier arrangement can be adapted to various vehicle shapes, but the production cost increases significantly
Solution Approach 1:
The profile body is divided into multiple profile segments that can be separately produced from standard raw profiles and then joined together. This segmentation allows the use of standardized manufacturing processes for each segment while enabling flexible assembly to create different overall shapes, thereby reducing production costs while maintaining adaptability to various vehicle contours.
Solution Approach 2:
The invention uses universal connecting structures (connecting elements with connecting receptacles) that can join profile segments in various configurations. These standardized connecting mechanisms can accommodate different vehicle shapes without requiring custom-made components, enabling the same basic components to serve multiple vehicle contour adaptations.
2Adaptability or versatility
If custom-made side supports are produced to adapt to different vehicle contours, then the carrier arrangement can be adapted to various vehicle shapes, but the device becomes heavier
Solution Approach 1:
By segmenting the profile body into modular sections that can be joined using standardized connecting elements, the design avoids the need for heavy custom-made side supports. Each segment can be optimized for its specific function and joined efficiently, reducing overall weight while maintaining the ability to adapt to different vehicle contours.
Solution Approach 2:
The profile segments can be produced from standard raw profiles with consistent cross-sectional parameters, and their arrangement (angular or curved) is achieved through the configuration of connecting elements rather than by changing the fundamental parameters of the support structure itself. This maintains structural efficiency and minimizes weight.
3Ease of manufacture
If profile segments are joined using traditional methods, then the connection may be simpler, but the structural strength and stability are reduced
Solution Approach 1:
The connecting element is designed as a separate component that interfaces with connecting receptacles on adjacent profile segments. This segmented approach allows for standardized, easy-to-manufacture components while the interlocking geometry of the connecting elements and receptacles provides strong mechanical joints that maintain structural integrity.
Solution Approach 2:
The connecting element combines multiple functions: it provides mechanical joining strength, allows for angular or curved configuration, and enables easy assembly. By merging these functions into a single component that works with the profile segments, the design achieves both ease of manufacture and high structural strength.
Data Source
Figure 1~2
Figure 3~5
Figure 6~10
AI summary
A support arrangement (10) for a trailer coupling (90) or a load carrier (95), wherein the support arrangement comprises a cross member (20) and a bracket (11) arranged on the cross member (20) and at least one profile body (35) as part of the cross member (20) or optionally side members (30) connected to the cross member (20), wherein the profile body has at least one circumferential wall (41) to define an interior space (42).The profile body has at least two profile segments (50-52) whose circumferential walls (41) are connected to each other at their ends in a miter angle (58-60) oblique to the respective longitudinal extension direction (54-57) of the profile segment, and that the adjacent profile segments are connected by means of a common circumferential wall (41) integral with both profile segments and/or by means of at least one retaining projection (65-365) projecting in front of the circumferential wall (41) of one profile segment towards the other profile segment and connected to the circumferential wall of the other profile segment.