US20180207698A1 - Extruded Profile Produced with Rotating Shaping Dies - Google Patents

Extruded Profile Produced with Rotating Shaping Dies Download PDF

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Publication number
US20180207698A1
US20180207698A1 US15/742,022 US201615742022A US2018207698A1 US 20180207698 A1 US20180207698 A1 US 20180207698A1 US 201615742022 A US201615742022 A US 201615742022A US 2018207698 A1 US2018207698 A1 US 2018207698A1
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Prior art keywords
profile
cross
profile according
variation
thickness
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US15/742,022
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English (en)
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Mark Jansson Kragh
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Priority claimed from PCT/SE2016/050684 external-priority patent/WO2017007411A1/en
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Publication of US20180207698A1 publication Critical patent/US20180207698A1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/02—Making uncoated products
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/02—Making uncoated products
    • B21C23/04—Making uncoated products by direct extrusion
    • B21C23/14—Making other products
    • B21C23/142—Making profiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/02—Making uncoated products
    • B21C23/04—Making uncoated products by direct extrusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/02—Making uncoated products
    • B21C23/04—Making uncoated products by direct extrusion
    • B21C23/08—Making wire, bars, tubes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C25/00—Profiling tools for metal extruding
    • B21C25/02—Dies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C25/00—Profiling tools for metal extruding
    • B21C25/02—Dies
    • B21C25/025—Selection of materials therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C25/00—Profiling tools for metal extruding
    • B21C25/08—Dies or mandrels with section variable during extruding, e.g. for making tapered work; Controlling variation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C35/00—Removing work or waste from extruding presses; Drawing-off extruded work; Cleaning dies, ducts, containers, or mandrels
    • B21C35/02—Removing or drawing-off work
    • B21C35/023—Work treatment directly following extrusion, e.g. further deformation or surface treatment
    • B29C47/32—
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/12—Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/13—Articles with a cross-section varying in the longitudinal direction, e.g. corrugated pipes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/256—Exchangeable extruder parts
    • B29C48/2568—Inserts
    • B29C48/25686—Inserts for dies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/285—Feeding the extrusion material to the extruder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/30—Extrusion nozzles or dies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/301—Extrusion nozzles or dies having reciprocating, oscillating or rotating parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/302—Extrusion nozzles or dies being adjustable, i.e. having adjustable exit sections
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/35—Extrusion nozzles or dies with rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C25/00—Profiling tools for metal extruding
    • B29C47/0019—
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/3001—Extrusion nozzles or dies characterised by the material or their manufacturing process
    • B29C48/3003—Materials, coating or lining therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/305—Extrusion nozzles or dies having a wide opening, e.g. for forming sheets
    • B29C48/31—Extrusion nozzles or dies having a wide opening, e.g. for forming sheets being adjustable, i.e. having adjustable exit sections
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/305—Extrusion nozzles or dies having a wide opening, e.g. for forming sheets
    • B29C48/315—Extrusion nozzles or dies having a wide opening, e.g. for forming sheets with parts oscillating relative to each other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/32—Extrusion nozzles or dies with annular openings, e.g. for forming tubular articles
    • B29C48/325—Extrusion nozzles or dies with annular openings, e.g. for forming tubular articles being adjustable, i.e. having adjustable exit sections
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/32—Extrusion nozzles or dies with annular openings, e.g. for forming tubular articles
    • B29C48/33—Extrusion nozzles or dies with annular openings, e.g. for forming tubular articles with parts rotatable relative to each other
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29L2007/00—Flat articles, e.g. films or sheets
    • B29L2007/001—Flat articles, e.g. films or sheets having irregular or rough surfaces
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    • B29L2023/00—Tubular articles
    • B29L2023/22—Tubes or pipes, i.e. rigid

Definitions

  • the present invention relates to a new principle to design profiles, profile segments, beams, elements for absorption of kinetic energy and surfaces/panels by varying the wall thickness along (_t)+across extrusion or pultrusions direction, making reinforcing patterns ( 2 , 3 ), vary the profile thickness (T, _t), and in some cases vary, cross-sectional area (_A FIG. 11, 12 , 15.2 angles ( 10 , 11 , FIG. 1 ) and pattern ( 2 , 3 , FIG. 1 ) which raises profile segments/panels resistance to bending, compression and buckling, relative to the amount of material used, enabling optimum performance for the purpose they are to serve, with minimum weight and minimum use of raw materials.
  • the invention can be done in various forms in a number of different ways for different applications, with various requirements and is applicable to extrusion and pultrusion of plastically deformable materials and material combinations for example metal, metal composite, plastic, plastic composite, wood based composites, clay, rubber or reinforced rubber formed to profile by a process comprising a tool with one or more fixed parts partially predefining the profile's appearance/cross section before the profiles final shape is defined to a fixed or varied cross section when the material passes rotating body can be patterned or smooth and whose position in some embodiments of the invention may vary relative to other bearing surfaces or rotating bearing surfaces in the tool with which they define profiles final shape, whether rotating dies used are patterned or not.
  • An object of the example embodiments of the disclosure is to provide an improved extruded profile. This object is partly achieved by the features of the independent claims.
  • an extruded profile having a longitudinal direction X and a transverse direction Y, and manufactured by dynamic extrusion/pultrusion of plastically/thermally deformable material with one or more static array elements with static bearing surfaces which in cooperation with one or more rotating dies whose rotating bearing surfaces completely or partly defines a profile cross-sectional shape that comprises two different thickness values in a longitudinal cross-section and/or a transverse cross-section.
  • the profile cross-sectional shape comprises at least two different thickness values in the longitudinal cross-section.
  • the profile cross-sectional shape comprises at least two different thickness values in the transverse cross-section.
  • the difference between a maximum thickness value and a minimum thickness value for at least one cross sectional shape is in the range between 2%-80%.
  • the difference between a maximum thickness value and a minimum thickness value for at least one cross section is in the range between 4%-50%.
  • the difference between a maximum thickness value and a minimum thickness value for at least one cross section is in the range between 5%-20%.
  • the thickness, as seen in the vertical direction Z, is varied for a given width along the transverse direction Y for any transverse cross-section.
  • the thickness, as seen in the vertical direction Z, is varied for a given length along the longitudinal direction X for any longitudinal cross-section.
  • the shape of the transverse cross section is varied for a given length along the longitudinal direction X.
  • a variation of the thickness for a given width is any one of a linear variation, non-linear variation, and step-wise variation. Other variations are also conceivable depending on the use and installation of the profile.
  • the profile cross-sectional shape defines a pattern extending in a direction different than the longitudinal direction and the transverse direction.
  • the pattern comprises at least one indentation and at least one projecting region.
  • the pattern is part of a repetitive pattern extending in the directions of the profile.
  • the at least one reinforced region is at least partly or entirely a diagonal-extending region, a polygon-shaped region such as a circular-shaped region, an elliptic-shaped region, a triangular-shaped region or the like, as seen in the longitudinal direction and in the transverse direction.
  • the profile comprising at least two different transverse cross sectional shapes along the longitudinal direction X, and at least two different longitudinal sectional shapes along the transverse direction Y.
  • the difference between said at least two different thickness values is provided by a variation of the profile thickness in the profile longitudinal direction.
  • an extruded profile according to the example embodiments as mentioned herein is particularly useful as a vehicle structure profile.
  • the profile can be used as an impact beam, impact absorbing beam or the like, such as a bumper impact beam.
  • the extruded profile can be used and installed in several different types of structures and systems.
  • pattern may refer to any type of region defined (or obtained) by the dynamic extrusion/pultrusion method as mentioned above, which typically at least partly or entirely defines a profile cross-sectional shape that comprises two different thickness values in a longitudinal cross-section and/or in a transverse cross-section.
  • the pattern may sometimes also be referred to as a reinforced region, a reinforced pattern, stiffening pattern, stiffeners, pattern segment or segment, or simply as a pattern.
  • the pattern comprises at least one indentation and at least one projecting area.
  • Extruded/pultruded materials often have a 15 better material property (higher strength) in the utmost millimeters of the surface and consequently it always results in maximum material performance in the surface.
  • the composite fibers and/or powder settles according material veining and thus provide maximum performance in the desired direction.
  • the methodology is also useful for optimizing the lamp-posts, sign holders and other elements in the traffic environments, as well as all profiles and beams that are included in some form of load cases.
  • the method makes it possible to extract the materials and weight saving potential that profile production with rotating dies give after the last development stages and innovations:
  • patent SE504300 (C2) and the patent SE514815 (C2) may be said to describe the procedure for extrusion with rotating dies acc. Pierre Hamel instructions, while patent applications 0702030-8 and 0702659-4 describes new methods and approaches enabling and in some cases is a prerequisite for producing the profiles described in this patent.
  • Production with rotating dies members are possible in all types of pultrusion and extrusion plants, with minimal or no adaptation needs of the facility, including hydraulic metal extrusion lines, screw extruders for rubber/plastic, conformextrusions machines and pultrusion machines, meaning that there is much good industrial capacity built to produce optimized profiles, segments and surfaces designed according to the methodology of the present invention.
  • the purpose of the invention is to by optimized design, rationally reduce weight, raw material consumption, energy consumption and emissions in the stage of manufacturing and use the profiles, beams, beam segments and areas having property improving designs and/or thickness variations that utilize the capabilities of rotating dies in a way that conventionally designed profiles, beams and surfaces can not make.
  • the invention relates to a new way to design, lighter, stronger, stiffer material efficient profiles ( 6 , 26 ,) Surfaces ( 22 ), beam segments ( 4 ), and energy absorbing members ( 6 ) and structures ( 23 ), with the desired behaviour patterns ( 7 FIG.
  • Different embodiments and applications of the invention makes it possible to improve the weight/strength ratio up to and in some cases over 50% in actual components with equal or better performance and with optimized characteristics (for example. deformation behaviour, natural frequency, etc.), enabling it to make better and more fuel-efficient cars, vehicles, airplanes, boats, with maintained safety and stronger structures that are lighter and less expensive.
  • Optimized profile With optimized profile it is meant a profile manufactured with dynamic extrusion or pultrusion manufactured with reinforcing patterns ( 18 , 19 , 20 , 21 ) and/or goods variation (_t, _A) that gives the optimized profile a higher strength/weight ratio than a corresponding profile with the same amount of material and cross layout without reinforcing patterns and goods variation has.
  • the patterns of the optimized profile can be customized to achieve maximum strength, stiffness, ability to absorb kinetic energy, be resistant to buckling, compression, have different properties in different directions etc.
  • Optimized surface With optimized surface it is mean an essentially flat profile (see FIG. 8 .) manufactured with dynamic extrusion or pultrusion with reinforcing pattern and/or goods variation which gives the optimized profile a strength/weight ratio and buckling resistance that is higher than a corresponding surface with the same amount of material and cross section layout without reinforcing patterns and goods variation has.
  • the optimized surface patterns can be customized to get maximum strength, stiffness, ability to absorb kinetic energy, buckling resistance, compression resistant, have different properties in different directions, etc.
  • the optimized surface can also be bent or profile into a profile which can have patterns on either in or outside or both inside and outside (if the optimized surface as the starting substance has pattern/ribs on both sides). In this way one can achieve optimized beams and profiles that are both open, half open (U profile) and closed (hollow), with relatively simple and inexpensive tools without the die core portion (see FIG. 211 pos 203 ). This is for three reasons:
  • Dies (see FIG. 203 item 206 ) with core member ( 211 ) is expensive and more difficult to manufacture than dies without core portion (see FIG. 11, 12, 13 ) at the same time as they are sensitive to fatigue.
  • Pultrusion In contrast to the extrusion means the profile drawing.
  • Pultrusion generally means that a continuous fibre bundle impregnated with liquid resin drawn through a heated die, but pultrusion is also used for shaping metal tubes and profiles. Resin impregnation occurs in a resin bath. The most common material is glass-reinforced unsaturated polyester. Other core epoxy resins and PolyUrethane are used depending on the application. Often used fibrous material in the form of woven or felt fabric, resulting fibre beam to achieve strength in the transverse direction. Pre-preg fibres (Fibres that are pre-impregnated with resin), can also be used.
  • the rotating shaping die members can be with pattern/variation as well as smooth or a combination of both.
  • the rotating shaping die members can be raised and lowered independently of other cycles in the process.
  • Die Generally, the name used by professionals for rofile production tools.
  • Rotating die Rotating profile-shaping member/organ of the tool for dynamic extrusion/pultrusion
  • Process collapse/breakdown Generic name for the failure of the start up of extrusion/pultrusion or problems at billet exchange, production, etc. that results in production stop. The high proportion of process-breakdowns has made the industrialization of the production of profile with rotating dies very problematic.
  • Pressure drop Reduction of pressure by the tool is a result of area-reduction, plastic exemplary work and friction. At metal extrusion converted large amounts of energy to heat, as a result of pressure. By “pressure drop balancing”—making adjustments to the pressure drop in the tool, the outgoing material get the same speed in all parts.
  • Imbalance means that the outgoing material will or want to come out with higher or lower speed at certain parts of the profile cross-section.
  • a profile extruded in a tool with the imbalance may be less resistant (due to internal tensions), tend to dent or bend and at the extrusion with rotating dies result is often the process breakdown.
  • Static Bearing Surface A bearing surface the extruded material is forced to pass at a relative speed of outgoing profile speed, because it is static, so that means there is a speed difference between the static bearing surface and the extruded material, resulting in a lot of friction and heat.
  • a rotating bearing surface is a surface of the rotating die/member that defines the profile cross-section, making patterns possible as well as wall-thickness variation.
  • a rotating bearing surface in general generates much less resistance/friction against the flowing material than a static bearing surface, which previously has created major problems with the imbalance between the different parts of the profile cross-section, which is defined by the rotating bearing surfaces and the parts that are defined by static bearing surfaces. This has often resulted in the process breakdown at start up.
  • profile manufacturing with use of present inventions device and method the problems with this, is radically reduced, through the gripping, steering and pulling of the profile in the right direction already in the tool. If you lift the rotating bearing surfaces at start up and let the gripping, steering puller go into the tool, elimination of deviating profile that can cause process failure is achieved.
  • Pre-Bearing/Pre-Bearing Surface The surface area that the extruded material passes just before it comes to the rotating die/forming member and its rotating bearing.
  • the pre-bearing brings down the material cross section so much so that the subsequent rotating die wont have to take up unnecessarily large forces from the extruded material.
  • Pre-bearing has in combination with preceding shape in the die upstream a central role for control and/or redulation of material flows through the die.
  • Puller/Profile Puller At the extrusion of metal profiles, it is customary that when one has squeezed out enough profile to reach the ordinary puller (usually 3-7 meters from the die) to stop extrusion, grip profile and then pull the profile and then re-start the extrusion. Some modern plants use dual-pullers, which means increased productivity and reduction of the number of stops and downtime.
  • Griping & steering pulling device In order to be able to make a plurality of the profiles shown in the drawings, it requires a special device a so called gripping & steering puller and procedure shown in the patent application 0702659-4.
  • Gripping steering puller enables efficient, repetitive, serial production with rotating shaping bearing surfaces during extrusion of thin profiles, with great variety of goods thickness, asymmetric profiles, with deep tread depth, “Weak” profiles (profile with low intrinsic stiffness) and weak profile segments (segments with low intrinsic stiffness), “flat” broad segments (see FIG. 8 ) who usually like to follow around the rotating die due to adhesion.
  • Griping puller can eliminate or minimize process breakdowns and enable start-up and ongoing efficient production of extruded profiles with rotating dies, which would otherwise be unthinkable due several factors:
  • V deep patterns relative wall thickness and steep angles on the patterns.
  • the present invention enables a variation of the thickness and tread depth, in reality, by taking into account factors such as variation of the pressure drop and the outlet rate, both of which vary when varying the outlet area/cross section of the profile:
  • a reduced outlet area increased pressure drop and at constant speed on the feeding of material into the extrusion/pultrusion die the result is a higher outlet speed and potentially big problems with increased temperatures and intermittently varying outlet speed of profile: for example, a halved outlet area result in doubled outlet speed at continuous feeding of extrusion material, which more or less inevitably leads to large process problems with varying quality on the basis profile and is likely to result in process breakdown.
  • extrusion ratio the materials area from ingots in relation to the outgoing profile area
  • Flaking is a phenomenon that occurs when you try to extrude/pultrude in high speed and outgoing profile has problem with holding together, due to the forces of friction between the outgoing profile and bearing surfaces and area reduction, is exceeding or approaching outgoing materials maximum speed and cracks which generally goes across extrusion/pultrusion direction.
  • An increased area reduction results in other words, in increase of the risk of scaling, while speed is increased on the output profile, if one does not take this into account.
  • feeding material into the extrusion/pultrusion tool result in the profile goes faster when there is a reduced cross-sectional area (as it would be wise to rather have a reduced exit speed to avoid cracking, flaking and/or overheating of outgoing material.
  • FIGS. 1, 1A and 1B schematically show an example embodiment of an extruded profile according to the disclosure in the form of a bumper beam;
  • FIG. 2A shows an example embodiment of the extruded profile in FIG. 1 and FIG. 1A-1B ;
  • FIG. 2B shows cross section of the example embodiment of the extruded profile in FIG. 1 and FIG. 1A-1B ;
  • FIG. 3A schematically shows another example embodiment of the extruded profile
  • FIG. 3B shows a cross section along A-A and B-B in FIG. 3A ;
  • FIGS. 4A, 4B and 5 schematically show various modes of an example embodiment of an extruded profile according to the disclosure in the form of a bumper beam;
  • FIGS. 6 and 7 schematically show various example embodiments of an extruded profile according to the disclosure
  • FIG. 8 schematically shows an example embodiment of a pattern of an extruded profile according to the disclosure
  • FIG. 9 schematically shows an example embodiment of an extruded profile according to the disclosure in the form of a framework
  • FIGS. 10, 10 A-A, 10 B-B schematically show various example embodiments of an extruded profile according to the disclosure
  • FIGS. 11-15 schematically show various example embodiments of an apparatus and method for manufacturing an extruded profile according to the disclosure
  • FIGS. 201, 202A-202B, 203, 204A-204C schematically show further details of various example embodiments of an apparatus and method for manufacturing an extruded profile according to the disclosure
  • FIGS. 301-304 a schematically show further details of various example embodiments of an apparatus and method for manufacturing an extruded profile according to the disclosure.
  • FIG. 1 shows the optimized profile segments of a bumper beam ( 6 ) with optimized patterned segments ( 4 ) according to the present invention, where the optimized segment ( 4 ) get gained increased compression/buckling and dent resistance from transverse ( 2 ) and longitudinal ( 3 ) reinforcements with height (_t) according to a pattern that provides enhanced thickness (T) in relation to the thin goods ( 1 ) and where the optimized segment ( 4 ) transforms into the corner segments ( 5 ) are angled ( 10 , 11 ) together with the along and transverse reinforcements to control the deformation at a compression where corner segments ( 5 ) are forced together and in order to obtain the maximum energy absorption, with steady force at the crash without beam segment 5 suddenly collapses and give in.
  • the segment of FIG. 1 gives a light, strong bumper beam that provides uniform deceleration with high energy absorption capacity without sudden collapse.
  • an extruded profile 6 As illustrated in the figures herein, for example FIGS. 1, 1 a and 1 b , there is provided one example embodiment of an extruded profile 6 .
  • the extruded profile is here described in relation to a bumper beam.
  • other types of profile and beams are readily conceivable such as vehicle structure profiles.
  • the extruded profile has a longitudinal direction X, a transverse direction Y and a vertical direction Z.
  • the extruded profile is manufactured by dynamic extrusion/pultrusion of plastically/thermally deformable material with one or more static array elements with static bearing surfaces which in cooperation with one or more rotating dies whose rotating bearing surfaces completely or partly defines a profile cross-section, in particular a cross-sectional shape.
  • FIG. 1 a shows part of a transvers cross section of the profile shape.
  • the profile cross-sectional shape comprises two different thickness values in the transverse cross-section.
  • FIG. 1 b shows part of a longitudinal cross section of the profile shape. Further, as shown in e.g. FIG. 1 b , the profile cross-sectional shape comprises two different thickness values in a longitudinal cross-section.
  • the figures illustrate an extruded profile having a profile cross-sectional shape that comprises two different thickness values in a longitudinal cross-section and two different thickness values in a transverse cross-section.
  • the extruded profile may only have a profile cross-sectional shape that comprises two different thickness values in the longitudinal cross-section.
  • the extruded profile may only have a profile cross-sectional shape that comprises two different thickness values in the transverse cross-section.
  • the cross-sectional shape may of course include any other number of different thickness values.
  • the profile cross-sectional shape comprises at least two different thickness values in the longitudinal cross-section and/or at least two different thickness values in the transverse cross-section.
  • That the extruded profile has a profile cross-sectional shape that comprises at least two different thickness values in the longitudinal cross-section and at least two different thickness values in the transverse cross-section can be readily appreciated from the various figures, showing e.g. a linearly varied thickness of the cross sectional shape, a non-linearly varied thickness of the cross sectional shape or a multiple step-wise varied thickness of the cross sectional shape.
  • the transverse cross-section extends in the transverse direction Y and in the vertical direction Z. Furthermore, the transverse cross-section comprises at least two different thickness values T1 and T2, as seen in the vertical direction Z.
  • FIG. 1 a shows a part of a transverse cross-section of the profile in FIG. 1 .
  • the extruded profile has been manufactured to form a profile with a transverse cross section having at least a first thickness value T1 and a second thickness value T2.
  • the first thickness value T1 may correspond to a maximum thickness value
  • the second thickness value T2 may correspond to a minimum thickness value.
  • the longitudinal cross-section extends in the longitudinal direction X and in the vertical direction Z. Furthermore, the longitudinal cross-section comprises at least two different thickness values T3 and T4, as seen in the vertical direction Z.
  • FIG. 1 b shows a part of a longitudinal cross-section of the profile in FIG. 1 .
  • the extruded profile has been manufactured to form a profile with a longitudinal cross section having at least a first thickness value T3 and a second thickness value T4.
  • the first thickness value T3 may correspond to a maximum thickness value
  • the second thickness value T4 may correspond to a minimum thickness value.
  • the difference between a maximum thickness value Tmax and a minimum thickness value Tmin in a cross-sectional shape is in the range between 2%-80%.
  • the difference between a maximum thickness value and a minimum thickness value for at least one cross section is in the range between 4%-50%.
  • the difference between a maximum thickness value and a minimum thickness value for at least one cross section is in the range between 5%-20%.
  • the thickness is varied for a given width Ly.
  • the variation of the thickness is varied in step-wise fashion.
  • the thickness can be varied in several different ways. That is, a variation of the thickness for a given width can be any one of a linear variation, non-linear variation, and/or step-wise variation. Other variations are also conceivable depending on the use and installation of the profile, which are further illustrated by the figures hereinafter.
  • the thickness is varied for a given length Lx.
  • the variation of the thickness is varied in step-wise fashion.
  • the thickness can be varied in several different ways. That is, a variation of the thickness for a given length can be any one of a linear variation, non-linear variation, and/or step-wise variation. Other variations are also conceivable depending on the use and installation of the profile, which are further illustrated by the figures hereinafter.
  • the thickness as seen in the vertical direction Z, is varied for a given width Ly along the transverse direction Y for any transverse cross section.
  • the shape of the transverse cross section is varied for a given length along the longitudinal direction X.
  • the profile cross-sectional shape defines a pattern 2 , 3 , 400 extending in a direction different than the longitudinal direction and the transverse direction.
  • Further examples of patterns or so called reinforced regions extending in a direction different than the longitudinal direction and the transverse direction are illustrated in e.g. FIGS. 2A, 2B, 3A, 3B , and FIGS. 6-9 .
  • the pattern comprises at least one indentation and at least one projecting region.
  • the pattern is part of a repetitive pattern extending in the directions X, Y and Z of the profile, see e.g. FIGS. 1, 1A, 2A, 2B, 3A, 3B , and FIGS. 6-9 .
  • the pattern as illustrated herein typically provides for an improved strength compared to non-patterned profile.
  • the pattern is at least partly or entirely a diagonal-extending region (see FIGS. 1, 1A and 1B ), a polygon-shaped region such as a circular-shaped region ( FIG. 7 ), an elliptic-shaped region, a triangular-shaped region ( FIG. 8 ) or the like, as seen in the longitudinal direction and in the transverse direction.
  • the profile comprising at least two different transverse cross sectional shapes along the longitudinal direction X, and at least two different longitudinal sectional shapes along the transverse direction Y, which may be gleaned from FIG. 10 although only one cross section and one longitudinal section are shown by FIGS. 10 A-A and 10 B-B.
  • the difference between the at least two different thickness values T1 and T2 is provided by a variation of the profile thickness in the profile longitudinal direction X.
  • the variation in thickness can also be varied in both the transverse direction Y and the longitudinal direction X.
  • FIGS. 2-10 further example embodiments are provided that may incorporate any one of the features, aspects or examples as described in relation to FIGS. 1, 1 a and 1 b above.
  • FIG. 2A shows an example of an optimized bumper beam seen from the top with front ( 14 ), back ( 13 ) and optimized top ( 4 ) visible.
  • FIG. 2B section A-A is a cross-section of the bumper beam ( FIG. 2A ), which showing how the optimized beam segments ( 4 ) are bent inward center at a collision when the front ( 14 ) of the beam is pressed against the back ( 13 ) which results in the optimized segments are pressed together completely (bent toward the beam middle in direction of the arrows, so the optimized segments is double-folded between the rear segment ( 13 ) and the compression preventing segment ( 15 ) whose depth ( 16 ) together with the double-folded optimized segments ( 4 ) patterned thickness (T) eliminates the bumper beam will completely flat and weak, at a hard collision, which can save lives.
  • FIG. 3A shows a side bumper beam with optimized segments ( 4 ), front ( 14 ) and back ( 13 ).
  • FIG. 3B shows the section A-A: B-B, the pattern provides a cyclical goods variation with low consumption of material giving a high resistance against bending, buckling, compression and dent.
  • FIG. 4A shows the unstressed bumper beam ( 6 )
  • FIG. 4B shows the bumper beam exposed to the load ( 4 F) a 2 cm wide area across the beam front and is attached to the ends at the fixing points (F, F, F, F) to the so-called crash boxes.
  • FIG. 5 shows the same collision simulation in FIG. 4 b and one can see how the optimized beam segments ( 4 ) absorps energy by bending inwards ( 17 ) with an even radius, without collapsing, which provides an optimum combination of strength, energy absorption, controlled deceleration without peaks and dips while the beam weighs 35% less than a beam without optimized segments with similar construction.
  • FIG. 6 shows an example of beam segments optimized for low weight combined with resistance against compression/dent, and stiffness of the beam segment without greater priority to mechanical energy absorption at deformation. It shows how the point load (Fk) distributed and spreading through the transverse ( 18 ), diagonal ( 19 and longitudinal ( 20 ) reinforcements. This segment is essentially flat since it is optimized for stiffness and strength, energy absorption has not been prioritized maximum (—Unlike the example of bumper beam in FIG. 5 ).
  • FIG. 7 shows an example of another embodiment of the a flat, patterned, beam segments, with goods variations in form of circular ( 21 ) reinforcements, transverse reinforcements ( 18 ) and a longitudinal reinforcement ( 20 ).
  • This beam segment gets a slightly “softer” characteristic in compression by the circular reinforcements than beam in FIG. 6 has.
  • the transverse reinforcements ( 18 ) combined with the longitudinal reinforcement ( 20 ) also gives a different characteristic of the load coming on narrow space or the point at k2 than the characteristic behaviour at the point load at point FK1 become: the transverse reinforcements ( 18 ) form together with the longitudinal reinforcement ( 20 ) and the corner segment ( 5 ) a very compression-resistant region that allows beam segment being “harder” against point loads at k2 than at FK1, thus varying patterns and combinations of reinforcements offers new, unique capabilities to a rational way to of producing lightweight beams, segments and products with tailored properties for different applications and uses.
  • FIG. 8 shows an example of how to design a pattern, to obtain a surface ( 22 ) that is light, stiff and resistant to buckling when loads to the surface normal.
  • the surface could be used to make the floors of an aircraft significantly lighter or to replace flat profiles or panels in ship decks, car decks, general construction, trucks, trains, trains, buses, consumer products etc.
  • the uses for lightweight surfaces with good rigidity are diverse not only due to weight, but also due to possibility of reducing raw material consumption and affect the natural frequency, stiffness, etc.
  • “Enhancement pattern” that one achieves through the patterns given by hollows in the rotating dies body ( 210 B FIG. 203 ) in the extrusion or pultrusion process (see FIG. 203 ), can be added relatively low cost and provide surface “sheets” which has significantly higher performance combined with low weight and reduced raw material cost, than would otherwise be possible.
  • FIG. 9 shows an example of a beam segment that is pronounced of an old classic so-called “latticework”, which usually is made by punching, milling, water cutting, or assembly of separate parts to high cost.
  • Friction Stir Welding is an appropriate method, since it provides joint without tensions or weakening defects in material micro-structure, including materials with extremely small crystalline in the size of 1 ⁇ able to maintain their properties relatively intact at FSW.
  • This processing may conveniently be done by water jet, which is relatively inexpensive, efficient and do not produce changes in the structure of materials from heat generation or tools or contamination cracking from vibration and cutting forces.
  • the end product is a very optimized beam segment or profile, so that the end result is a profile with fast, cyclical, diversified, cross-sectional area variations to making the areas of compensation of the areas to be machined away ( 24 ), so that the extrusion/pultrusion has a process in terms of simple profile to do with the relatively even cross sectional area along the profile, which works well in process and allows for greater variety in material thickness (_t).
  • the area-compensating areas ( 24 ) is machined away, it is a very light, strong and rigid profile/segment that have good quality and can be produced with a low proportion of scrap and low bearings costs.
  • FIG. 10 shows an example of a profile extruded in one step with 2 optimized beam segment of the type shown before in FIG. 9 , with the side segments 27 .
  • This profile can either be made in one step by pultrusion or extrusion with two rotating shaping dies (see FIG. 203 ) or by joining 2 pcs optimized beam segments ( 23 ) with 2 “Normal” segments ( 27 ).
  • FIG. 10 A-A you can clearly see how the pattern vary thickness and how to use it.
  • FIG. 10 B-B and its partial enlargement one can see how pattern involves a repetitive variation ( 212 ) of thickness as a result of the pattern of the rotating shaping dies (see FIG. 203 ).
  • FIG. 11 is shown how one can vary the thickness on an optimized profile ( 28 ), by varying the rotating die position, relatively static bearings.
  • FIG. 12 is shown how a profile ( 29 ) with the pattern both sides are given varying thickness, which varied and cessation patterns, by raising and lowering the rotating dies ( 110 ).
  • FIG. 13 shows how to make a “Zic-Zac” profile ( 30 ), by controlling the material in sometimes one and sometimes other direction with the rotating dies.
  • FIG. 14 has a profile segments acc.
  • FIG. 13 been used as waist during extrusion of an I-beam ( 32 ) which can thus be given unique characteristics, it is easy to see how the rotating dies ( 33 , 34 ) is essentially giving a profile with constant cross-sectional area where the area average A 1 , A 2 , and A 3 is in principle the same, even though the profile has a “pleated” waist.
  • This allows the extrusion process to be smooth, with a constant area of cross section results in a constant material flow through the tool which gives low pulsations in terms of speed, power and pressure in both billet, tools, bearings and extrusion line.
  • FIG. 15 is shown how to vary the cross-sectional and pattern along an imaginary product ( 35 ), to be different properties at different locations.
  • FIG. 201 Displays overview with complete extrusion line provided with gripping & steering puller device ( 230 ) complete with stretching device ( 231 ), where the rotating dies ( 10 ) are in their external positions so that the gripping & steering puller ( 230 ) can go right into the die ( 6 ) and where the gripping & steering puller ( 230 ) is ready to take Receive/embrace, grip, pull and steer outgoing material from die and steer/pull it up to the ordinary gripper ( 213 ) and puller ( 214 ).
  • FIG. 202A + 202 B shows how the device and method interact to provide a stable start-up:
  • FIG. 202A shows the puller device is ready for process starting with gripping & steering puller ( 230 A) inside the die between the rotating dies ( 210 A), ready to grip, steer and pull outgoing material before it may deviates and cause process breakdown.
  • FIG. 202B shows how the gripping & steering puller ( 230 B) has gripped the profile and pulls it in the desired direction, while rotating dies ( 10 B) has gone into production mode and started designing outgoing material before it can deviate and cause process breakdown.
  • gripping & steering puller 230 B
  • rotating dies 10 B
  • FIG. 202B shows how the gripping & steering puller ( 230 B) has gripped the profile and pulls it in the desired direction, while rotating dies ( 10 B) has gone into production mode and started designing outgoing material before it can deviate and cause process breakdown.
  • FIG. 204A shows how the gripping & steering puller ( 230 A) has entered in the extrusion press past the front plate and the support plate all the way into the extrusion die ( 206 ) ready to grip, steer and pull outgoing materials in the right direction long before extrusion plant's ordinary puller ( 14 a ) and ordinary gripping device ( 13 a ) can do it.
  • FIG. 204B shows how the gripping & steering puller ( 30 B) has grabbed and takes the output material and goes through ordinary gripping device ( 213 b ) so that ordinary puller ( 14 a ) is able to take over when outgoing material reached regular grippers/puller.
  • FIG. 204C shows how the gripping puller has pulled out outgoing materials to the ordinary gripping device 213 C which thereby able to grip the profile which can thus stretched-controlled by ordinary puller ( 214 c ) start pulling in the outbound profile—without manual intervention, stop interruptions or risk for process breakdown caused by deviating outgoing material.
  • Gripper-puller ( 230 C) has released profile and moved in sideways before the next startup or before billet exchange where it can ensure that the profile is stretched-drawn at cutting of extrusion lines that lack dual ordinary pullers.
  • FIG. 301 shows optimized profile ( 322 ) with pattern on inside, made by rotating dies ( 310 ), sitting in the core portion of the tool.
  • movable bearing ( 318 ) enabling further opportunities to optimize the thickness and pattern.
  • One can also see how the combination of half-lowered bearing ( 318 b ) and completely raised rotating die ( 304 b ) results in a hollow section with the patterned inside and smooth outer surface ( 22 c ) thereof 318 b+ 304 b 322 c.
  • FIG. 302 shows how to produce optimized profiles with varied patterns by varying the position of rotary dies ( 4 a , 4 b ) relative to the adjustable bearing ( 18 b ).
  • FIG. 303 shows how to vary the thickness and pattern ( 322 a , 322 b , 322 c ) at extrusion of hollow section ( 322 ) by varying the position of rotary dies ( 4 a , 4 b , 4 c ) and adjustable bearings ( 18 a , 18 b ). This can of course, also be carried out during extrusion of non-hollow sections.
  • FIG. 304 shows a third embodiment of the invention where varying the thickness of the outgoing profiles, by varying the bearings ( 313 ) position.
  • FIGS. 304 a and 304 b shows the relationship between the bearings length ( 314 a , 314 b ) and profile thickness ( 315 a , 315 b ) kept reasonably constant at varied thickness, by allowing static bearing surface in fixed tool part cooperating with the bearings variable bearing length—which is important to get the balance flow and stable process.
  • the/the rotating shaping units ( 110 FIG. 11 +12+13+15, 210 FIG. 201, 203, 304 FIG. 302, 302, 303 ) is raised and lowered so that you get a variation in the average profile cross section area here called delta A (_A) corresponding by raising or lowering the rotating die units.
  • delta A a variation in the average profile cross section area
  • the beam cross-sectional area and strength is tailored to the needs and the load each portion of a beam or profile becomes exposed to. This is essential since most beams, profiles and profile segments are exposed to various major load at different locations and usually dimensioned the entire length after the point or piece of beam/the profile which is subjected to the greatest loads and thus becomes automatically oversized in other parts.

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CN107848182B (zh) 2021-04-30
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US20180193891A1 (en) 2018-07-12

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