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US 2018/0207698 A1Published application
Extruded Profile Produced with Rotating Shaping Dies
AssigneeReliefed AB
InventorMark Jansson Kragh
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AssigneeReliefed AB
InventorMark Jansson Kragh
Estimating the term…
A new way to design lightweight, strong, material efficient, extruded and pultruded profiles, profile segments (4) and surfaces produced in profile production with rotating dies creating superior resistance to compression, bending and buckling, higher energy absorption and right strength in the right place, by: varying the thickness along (_t)+across the direction of extrusion, making reinforcing patterns (2, 3), vary the profile thickness (t, _t), and in some cases vary angles (10, 11) and pattern (2, 3) which increases the profile segments/surface resistance against compression, bending and buckling relative to the amount of material used and resulting in that one can make optimized beams and surfaces that have superior properties in terms of strength/weight, stiffness/weight ratio, mechanical energy absorption/weight unit, deformation and natural frequency, thermal transfer capacity, the breaking of the laminar flow, increased/optimized surface for chemical and/or electrochemical reaction etc.
An extruded profile having a longitudinal direction (X) and a transverse direction (Y), and manufactured by dynamic extrusion/pultrusion of plastically/thermally
Profile according to any one of the preceding claims, wherein said profile cross-sectional shape defines a pattern extending in a direction different than said longitudinal direction and said transverse direction.
Profile according to any one of the preceding claims, further comprising at least two different transverse cross sectional shapes along said longitudinal direction X, and at least two different longitudinal sectional shapes along said transverse direction Y.
Profile according to any one of the preceding claims, wherein the difference between said at least two different thickness values is provided by a variation of the profile thickness (T, _t, _A) in the profile longitudinal direction.
Profile according to any one of the preceding claims, wherein the surface resistance of said profile is reinforced against bending, denting and buckling, with stiffening patterns, stiffeners or segments (2, 3, 18, 19, 20, 21, 23) which increases resistance to bending, denting and buckling relative to the amount of material used.
Profile according to any one of the preceding
Profile according to any one of the preceding claims wherein the surface of the profile is provided with pattern that increases the peripheral surface and providing turbulent flow as elimination of the problems caused by the insulating effect of laminar flow in thermal transfer applications (heat exchange).
Profile according to any one of the preceding claims, wherein said profile is provided with stiffeners that takes out natural frequencies, sound and vibrations in order to get a quieter component.
Profile according to any one of the preceding claims, wherein the profile is reinforced in regions where most strength is needed, through increased cross-sectional area of the current area.
Profile according to any one of the preceding claims, wherein said profile comprises sections with different cross-sectional area achieved by varying the location of the rotary bearings.
Profile according to any one of the preceding claims, wherein the profile comprises sections of different cross-sectional area which have been accomplished by varying static bearing (318, 313) positioning.
Profile according to any one of the preceding claims, wherein the variation in led along is achieved by having one or more rotary dies (33, 34, 210, 310, 304), which has patterns or varied radius.
Profile according to any one of the preceding claims, wherein the variation of wall thickness along the led is achieved by a combination of one or more rotating dies that are patterned and that the rotating dies is raised/lowered.
Profile according to any one of the preceding claims, wherein the profile has variation of 2 sides of the profile segments.
Profile according to any one of the preceding claims, wherein several profile segments have variation.
Profile according to any one of the preceding claims, wherein one or more profile segments is “pleated” (32).
Profile according to any one of the preceding claims, wherein one or more profile of segments are “pleated” (32) in order to increase the compression resistance of the beam segment.
Profile according to any one of the preceding claims, wherein the beam/profile is made of a “plane” profile-surface with variation along led, that is profile bent or bent to the desired beam or component shape.
Profile according to any one of the preceding claims, wherein the “plane” surface-profile with variation/pattern along led is bent so that the profile/component will get variation/pattern on the inside, which results in an optimized beam with smooth outer surface.
Profile according to any one of the preceding claims, wherein the beam/profile made of that the “flat” profile-surface with variation along-led, with variations on both sides (30), which is bent into or press bent to the desired beam or component shape.
Profile according to any one of the preceding claims, wherein the profile is substantially having the same cross sectional area despite the along led variation (A1, A2, A3), making the profile easier to extrude.
Profile according to any one of the preceding claims, wherein the uniform cross sectional area is provided by 2 similar rotating dies on each side of the extruded material (32).
Profile according to any one of the preceding claims, wherein the profile is made stronger/stiffer with pattern/ribs (23) that increase resistance to buckling/compression of the sides that are subject to compression under load of the device.
Profile according to any one of the preceding claims, wherein the profile is provided with patterns that increase compression resistance on the beam sides exposed to compressive forces (F1, F2)
Profile according to any one of the preceding claims, wherein the patterned sides (4) is designed to be bent into the beam (17) and adds itself as a “distance” between the wall (13) and (14) to eliminate the beam is totally compressed and collapsed.
Profile according to any one of the preceding claims, wherein said profile is produced with one or more movable bearing inserts (313) in the tool.
Profile according to any one of the preceding claims, wherein it is produced with the tool constructed so that the bearing length (314a, 314b) increases when the profile thickness increases (315a, 315b) by making pre bearing becoming an extension of the bearing when the movable bearing insert (13) is in its outer position by making pre bearing align with and bearing in outer position.
Profile according to any one of the preceding claims, wherein raiseable/lowerable external rotating dies are combined with raiseable/lowerable adjustable pre bearing (18).
Profile according to any one of the preceding claims, wherein the device varies the speed/volume per time unit with which the input amount of material feed extrusion/pultrusions with, so that one either gets a so constant outlet speed as possible on the output profile, or decreases the discharge rate, to avoid risk of flaking/overheating of outgoing material, when the smaller profile area is run, by synchronizing supply with material amount of variation in the outgoing cross-sectional area and thickness profile.
Profile according to any one of the preceding claims, wherein said profile is any one of a vehicle structure profile, an impact absorbing beam, such as a bumper impact beam, or the like.
A method for producing an extruded profile according to any preceding claims, manufactured by dynamic extrusion/pultrusion of plastically/thermally deformable material with one or more static array elements with static bearing surfaces in conjunction with one or more rotating dies whose rotating bearing surfaces that are wholly or partly define the profile cross-sectional shape, wherein said method comprises the steps of varying the thickness profile (t, _T, _A) in the profile longitudinal direction.
A method according to any preceding method claim wherein the raising profile segments/surface resistance to bending, buckling and buckling, with stiffening patterns, strips or segments (2, 3, 18, 19, 20, 21,23,) which increases resistance to bending, buckling and buckling relative to the amount of material used.
A method according to any preceding method claim wherein said method comprises the steps of varying the speed/volume per time unit with which the input amount of material feed extrusion/pultrusion tool in order to either allow such constant outlet speed as possible on the output profile, or decrease the outlet velocity, for avoid the risk of flaking/overheating of outgoing material, when the smaller profile area is run, by synchronizing supply with material amount of variation in the outgoing cross-sectional area and thickness profile.
A method according to any preceding method claim wherein the method comprises the steps of varying the speed and/nor force with which the output profile is stretched by to adapt to variation in cross sectional area and initial speed of the outgoing material from the extrusion/pultrusion tool, so as to have such a constant tension force per cross-sectional area as possible on the outgoing profile, by synchronizing the tensile force and/or speed variation of the outgoing cross-sectional area and the amount of material with which the volume of materials/unit time as the extrusion/pultrusion tool is supplied with.
Dependencies are inferred from the claim text.