Variable Wall Thickness Tubular Support Structure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Modern production processes for metal structural supports often compromise between mass savings and strength, failing to efficiently produce supports with varying wall thickness without requiring mechanical or metal joining methods.
Innovation Solution
A tubular support structure with variable wall thickness is produced using a single piece of tubing, where the wall thickness can vary consistently over the length through a transition area, formed using an inner and outer tool apparatus, allowing for superior strength and reduced mass without mechanical joining, and can be made from various materials like steel, ceramics, and fiberglass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform wall thickness is used in tubular supports, then manufacturing simplicity is maintained, but mass savings are sacrificed
Solution Approach 1:
The patent applies local quality by varying the wall thickness of the tubular support along its length, creating regions of different thickness (thicker at ends, thinner in the middle) to optimize both strength requirements and mass reduction, rather than using uniform thickness throughout
Solution Approach 2:
The patent changes the geometric parameter of wall thickness along the length of the tube, transitioning from a constant parameter (uniform thickness) to a variable parameter (non-uniform thickness) to achieve mass savings while maintaining structural integrity
2Weight of moving object
If variable wall thickness is implemented, then mass savings are achieved, but manufacturing complexity increases
Solution Approach 1:
The patent uses preliminary action by forming the variable wall thickness profile during the initial extrusion or drawing process, rather than adding thickness variations afterward through secondary operations like welding or mechanical joining, thus managing complexity at the source
Solution Approach 2:
The patent introduces an intermediary tooling element (such as a mandrel or forming die) that enables the creation of variable wall thickness during the forming process, acting as a mediator between the uniform billet and the final non-uniform tube shape
3Strength
If mechanical joining methods are used for variable thickness sections, then structural integrity is maintained, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent merges the variable thickness profile into a single continuous extrusion or drawing operation, creating an integral structure without separate parts that would require mechanical joining, thus maintaining strength while reducing assembly complexity
Solution Approach 2:
Instead of joining separate uniform-thickness sections to create variable thickness, the patent inverts the approach by forming the variable thickness profile in a single continuous operation, eliminating the need for joining operations
Data Source
AI summary
A support structure may include a metallic tube having two opposing ends. The first end may have a first length, a first wall thickness, and a first outer diameter. The second end may have a second length, a second wall thickness, and a second outer diameter. A transition area may be disposed between the first length and the second length. The first wall thickness may be greater than the second wall thickness thereby providing variable thickness.