Variable Thickness Extrusion for Structural Attachment
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Solution Overview
Problem
Existing vehicle extrusions with uniform thickness require heavier materials to securely attach structural components, increasing weight and potentially compromising efficiency.
Innovation Solution
An extrusion with varying thickness sections, where a thinner section joins a thicker section, allowing for reduced mass while maintaining structural integrity through locally thickened areas and the use of flow drill screws for attaching sheets with optional adhesive layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If uniform thickness extrusion is used, then structural integrity is maintained, but mass increases
Solution Approach 1:
The extrusion features varying wall thicknesses with locally thickened sections positioned at specific locations to provide enhanced structural integrity and attachment points, while other sections maintain thinner walls to reduce overall mass. This non-uniform thickness distribution optimizes the strength-to-weight ratio by concentrating material where structurally necessary.
2Strength
If thicker sections are used throughout, then attachment strength is improved, but mass increases
Solution Approach 1:
The extrusion incorporates localized thickened sections specifically at areas requiring attachment points, while maintaining thinner wall thickness in non-critical sections. This selective thickening provides sufficient attachment strength without unnecessarily increasing the mass of the entire extrusion component.
Data Source
AI summary
A number of variations may include a product including an extrusion having an extruded profile including a first section having a first thickness and a second section having a second thickness wherein the second thickness is greater than the first thickness.