A device and method for designing lightweight, strong, material efficient, extruded and pultruded profiles, profile segments 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 and across the direction of extrusion, making reinforcing patterns varying the profile thickness, and in some cases varying angles and patterns which increases the profile segments/surface resistance against compression, bending and buckling relative to the amount of material used and resulting in the manufacturing of 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.

A threaded fastener having a prevailing torque feature and a method for forming same includes a barrel having a longitudinal axis. The barrel has a plurality of internal threads, each internal thread including a forward facing surface and a rearward facing surface. A first angle between the forward facing surface and a first lateral axis perpendicular to the longitudinal axis ranges from 20° to 40°. A second angle between the forward facing surface and the rearward facing surface ranges from 80° to 100°.

A threaded fastener having a prevailing torque feature and a method for forming same includes a barrel having a longitudinal axis. The barrel has a plurality of internal threads, each internal thread including a forward facing surface and a rearward facing surface. A first angle between the forward facing surface and a first lateral axis perpendicular to the longitudinal axis ranges from 20° to 40°. A second angle between the forward facing surface and the rearward facing surface ranges from 80° to 100°.

An electric vehicle, including, a user compartment and a front section including a portion of a vehicle chassis, a crash absorbing member located in the front section and connected to the portion of the vehicle chassis, the crash absorbing member including a first extruded profile, preferably an aluminum profile, having a main extension direction in a transverse direction (y) of the vehicle, whereby the extrusion direction of the first extruded profile extends substantially in the transverse direction (y) of the vehicle, and wherein further the first extruded profile includes at least two cells (C1, C2) being defined by outer walls and at least one intermediate wall separating the at least two cells (C1, C2), wherein the at least one intermediate wall has a main extension direction in the transverse direction (y) and a second extension direction which extends substantially in a vertical direction (z).

A process for forming extruded products using a device having a scroll face configured to apply a rotational shearing force and an axial extrusion force to the same preselected location on material wherein a combination of the rotational shearing force and the axial extrusion force upon the same location cause a portion of the material to plasticize, flow and recombine in desired configurations. This process provides for a significant number of advantages and industrial applications, including but not limited to extruding tubes used for vehicle components with 50 to 100 percent greater ductility and energy absorption over conventional extrusion technologies, while dramatically reducing manufacturing costs.

To obviate the above shortcomings, the present invention teaches an aluminum assembly comprising at least an aluminum member. Each aluminum member has a first coupling element and a second coupling element extended from two edges of the aluminum member. The first coupling element has a first groove section and a first protrusion. The first groove section has a first fastener and a second fastener. The second coupling element has a second groove section and a second protrusion. The second groove section has a third fastener and a fourth fastener. As such, the first coupling element of a first aluminum member may be detachably coupled to the second coupling element of a second aluminum member, and the second coupling element of the first aluminum member may be coupled to the first coupling element of a third aluminum member. An aluminum assembly of various forms may be constructed in this way.

A method for producing motor vehicle controls from extruded profiles and a motor vehicle control. A length section of an extruded profile strand is provided and this is either processed by cutting technology and divided into several extrusion profiles or is first divided into several extruded profiles and they are then processed via shear cutting. By means of a mechanical processing of the extrusion profiles, the motor vehicle controls are formed. The length section has a double T-shaped cross-section with a brace and two belts aligned perpendicular to the brace, wherein the end-side of the belts are connected to flanges. During manufacturing, a motor vehicle control is produced with a steering element, which comprises a middle part and two side arms. In the middle part as well as in the side arms, bearing housings are configured.

An extruded rail assembly including a first multi-channel extrusion having at least two tubular channels connected by a center rib, and having a joining end configured for joining at a predetermined angle to a joining end of a second multi-channel extrusion. The second multi-channel extrusion includes at least two tubular channels connected by a center rib, and having a joining end configured for joining at the predetermined angle to the joining end of first multi-channel extrusion. The joining ends of the first and second multi-channel extrusions are configured such that the center ribs complementarily engage as a joining surface.

A threaded fastener having a prevailing torque feature and a method for forming same includes a barrel having a longitudinal axis. The barrel has a plurality of internal threads, each internal thread including a forward facing surface and a rearward facing surface. A first angle between the rearward facing surface and a first lateral axis perpendicular to the longitudinal axis ranges from 20° to 40°. A second angle between the forward facing surface and the rearward facing surface ranges from 80° to 100°.

A threaded fastener having a prevailing torque feature and a method for forming same includes a barrel having a longitudinal axis. The barrel has a plurality of internal threads, each internal thread including a forward facing surface and a rearward facing surface. A first angle between the rearward facing surface and a first lateral axis perpendicular to the longitudinal axis ranges from 20° to 40°. A second angle between the forward facing surface and the rearward facing surface ranges from 80° to 100°.