Zigzag Protective Element Without Bending-Radius Weakening
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Solution Overview
Problem
Existing zigzag-shaped protective elements experience weakening due to bending radii during the manufacturing process, which compromises their ballistic protection effectiveness.
Innovation Solution
A method for producing a zigzag-shaped protective element by welding individual profiles at specific angles to form a preform, which is then hot-formed and form-hardened without the need for bending, thereby eliminating bending radii and maintaining material thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If flat plates are bent to create a zigzag-shaped protective element, then the zigzag shape is formed, but bending radii are created that reduce material thickness and weaken the protective element
Solution Approach 1:
The protective element is divided into multiple individual profiles that are welded together at angles to form the zigzag shape. This segmentation allows the zigzag configuration to be achieved through angular joints rather than bending, thereby avoiding the creation of bending radii that would reduce material thickness and compromise strength.
Solution Approach 2:
Instead of forming the zigzag shape by bending a continuous plate (conventional approach), the invention inverts the approach by assembling pre-formed straight profiles at angular orientations. This inversion of the manufacturing sequence eliminates the bending operation entirely, preserving material thickness and structural integrity.
2Shape
If large bending radii are used to minimize bending, then the zigzag shape is still formed, but the strength of the workpiece decreases
Solution Approach 1:
The protective element is divided into multiple individual profiles that are welded together at angles to form the zigzag shape. This segmentation allows the zigzag configuration to be achieved through angular joints rather than bending, thereby avoiding the creation of bending radii that would reduce material thickness and compromise strength.
Solution Approach 2:
Instead of forming the zigzag shape by bending a continuous plate (conventional approach), the invention inverts the approach by assembling pre-formed straight profiles at angular orientations. This inversion of the manufacturing sequence eliminates the bending operation entirely, preserving material thickness and structural integrity.
3Reliability
If individual profiles are welded at angles of 30° to 120°, then the zigzag shape is formed with improved projectile deflection, but the manufacturing process becomes more complex
Solution Approach 1:
The protective element is divided into multiple individual profiles that are welded together at angles to form the zigzag shape. This segmentation allows the zigzag configuration to be achieved through angular joints rather than bending, thereby avoiding the creation of bending radii that would reduce material thickness and compromise strength.
Solution Approach 2:
The invention specifies optimal angle ranges (30° to 120°) for welding individual profiles together. By optimizing this geometric parameter, the structure achieves improved projectile deflection capability while maintaining manufacturability. The parameter optimization balances performance requirements with manufacturing feasibility.
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 method ensures that the zigzag-shaped protective element maintains its necessary protective effect across its entire extent, without weakening in certain areas, thereby enhancing its ballistic resistance and stability.
Implementation Method 1
b) Welding the individual profiles to form a zigzag-shaped preform of the protective element to form at least one weld seam
Implementation Method 2
c) Inserting the preform into a hot forming tool, d) Forming the preform to form the zigzag-shaped protective element in the hot forming tool
Implementation Method 3
e) Form hardening the zigzag-shaped protective element in the hot forming tool
Data Source
Figure 1a~1c
Figure 2~4
Figure 5a~5c
AI summary
The invention relates to a method for producing a zigzag-shaped protective element (2) formed from a plurality of individual profiles (3, 4, 5, 6), comprising the following method steps: a) providing the individual profiles (3, 4, 5, 6), b) welding the individual profiles (3, 4, 5, 6) to form a zigzag-shaped preform (1) of the protective element (2) to form at least one weld seam (8, 10), the individual profiles (3, 4, 5, 6) being welded to one another at an angle (α) of 30° to 120°, c) placing the preform (1) in a hot-forming tool, d) forming the preform (1) to form the zigzag-shaped protective element (2) in the hot-forming tool, e) hardening the zigzag-shaped protective element (2) in the hot-forming tool. The invention further relates to a zigzag-shaped protective element (2), which is produced in particular according to the method according to the invention.