Extruded Profile Produced with Rotating Shaping Dies

Abstract

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.

Claims

1. 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 in a transverse cross-section.

2. Profile according to claim 1, wherein the difference between a maximum thickness value and a minimum thickness value in said cross-sectional shape is in the range between 2%-80%, still preferably in the range between 4%-50%, still preferably in the range between 5%-20%.

3. Profile according to claims 1-2, wherein the thickness, as seen in a vertical direction (Z), is varied for a given width along a transverse direction (Y) for any transverse cross section of said profile.

4. Profile according to claims 1-3, wherein the shape of the transverse cross section is varied for a given length along said longitudinal direction (X).

5. Profile according to claims 3-4, wherein a variation of the thickness for a given width is any one of a linear variation, non-linear variation, and step-wise variation.

6. 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.

7. Profile according to claim 6, wherein said pattern comprises at least one indentation and at least one projecting region.

8. Profile according to claim 6 or claim 7, wherein said pattern is part of a repetitive pattern extending in the directions (X, Y and Z) of the profile.

9. Profile according to any one of the claims 6-8, wherein said pattern 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.

10. 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.

11. 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.

12. 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.

13. Profile according to any one of the preceding claims, wherein the surface of the profile is provided with a pattern, which increases the peripheral surface, in order to increase thermal transfer capabilities.

14. 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).

15. 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.

16. 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.

17. 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.

18. 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.

19. 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.

20. 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.

21. Profile according to any one of the preceding claims, wherein the profile has variation of 2 sides of the profile segments.

22. Profile according to any one of the preceding claims, wherein several profile segments have variation.

23. Profile according to any one of the preceding claims, wherein one or more profile segments is pleated (32).

24. 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.

25. 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.

26. 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.

27. 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.

28. 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.

29. 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).

30. 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.

31. 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)

32. 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.

33. 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.

34. 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.

35. Profile according to any one of the preceding claims, wherein raiseable/lowerable external rotating dies are combined with raiseable/lowerable adjustable pre bearing (18).

36. 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.

37. 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.

38. 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.

39. 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.

40. 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.

41. 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.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0091] With reference to the appended drawings, below follows a more detailed description of embodiments of the disclosure cited as examples.

[0092] In the drawings:

[0093] 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;

[0094] FIG. 2A shows an example embodiment of the extruded profile in FIG. 1 and FIG. 1A-1B;

[0095] FIG. 2B shows cross section of the example embodiment of the extruded profile in FIG. 1 and FIG. 1A-1B;

[0096] FIG. 3A schematically shows another example embodiment of the extruded profile;

[0097] FIG. 3B shows a cross section along A-A and B-B in FIG. 3A;

[0098] 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;

[0099] FIGS. 6 and 7 schematically show various example embodiments of an extruded profile according to the disclosure;

[0100] FIG. 8 schematically shows an example embodiment of a pattern of an extruded profile according to the disclosure;

[0101] FIG. 9 schematically shows an example embodiment of an extruded profile according to the disclosure in the form of a framework;

[0102] FIGS. 10, 10 A-A, 10 B-B schematically show various example embodiments of an extruded profile according to the disclosure;

[0103] FIGS. 11-15 schematically show various example embodiments of an apparatus and method for manufacturing an extruded profile according to the disclosure;

[0104] 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;

[0105] FIGS. 301-304a schematically show further details of various example embodiments of an apparatus and method for manufacturing an extruded profile according to the disclosure.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

[0106] The present invention will in the following be described in various embodiments with reference to the accompanying drawings which of example show preferred embodiments of the invention, the invention is not limited to those in the drawings and descriptions exemplary embodiments, but

[0107] can by a technician be performed in other ways and with more combinations based on the description and appended claims with variations of profiles, profile segments and surfaces with varied patterns and thicknesses and profile segments and profiles with different configurations that look different from those in the exemplifying drawings on exhibited examples. The invention is comprised of all the possible combinations which can be achieved within the patent claims.

[0108] 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. By this, the segment of FIG. 1 gives a light, strong bumper beam that provides uniform deceleration with high energy absorption capacity without sudden collapse.

[0109] As illustrated in the figures herein, for example FIGS. 1, 1a and 1b, there is provided one example embodiment of an extruded profile 6. For the purpose of facilitating the description, the extruded profile is here described in relation to a bumper beam. However, other types of profile and beams are readily conceivable such as vehicle structure profiles.

[0110] The extruded profile has a longitudinal direction X, a transverse direction Y and a vertical direction Z.

[0111] 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.

[0112] FIG. 1a shows part of a transvers cross section of the profile shape. As shown in e.g. FIG. 1a, the profile cross-sectional shape comprises two different thickness values in the transverse cross-section.

[0113] FIG. 1b shows part of a longitudinal cross section of the profile shape. Further, as shown in e.g. FIG. 1b, the profile cross-sectional shape comprises two different thickness values in a longitudinal cross-section.

[0114] 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. However, it is to be noted that the extruded profile may only have a profile cross-sectional shape that comprises two different thickness values in the longitudinal cross-section. Alternatively, the extruded profile may only have a profile cross-sectional shape that comprises two different thickness values in the transverse cross-section.

[0115] In addition, it is to be noted that the cross-sectional shape may of course include any other number of different thickness values. Thus, it is only required that 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.

[0116] Turning again to FIG. 1a, 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. 1a shows a part of a transverse cross-section of the profile in FIG. 1. In this figure, 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. In some example, the first thickness value T1 may correspond to a maximum thickness value and the second thickness value T2 may correspond to a minimum thickness value.

[0117] Turning again to FIG. 1b, 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. 1b shows a part of a longitudinal cross-section of the profile in FIG. 1. In this figure, 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. In some example, the first thickness value T3 may correspond to a maximum thickness value and the second thickness value T4 may correspond to a minimum thickness value.

[0118] By way of example, 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%. In another example, 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%. In yet another example, 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%.

[0119] Further, as shown in FIG. 1a, the thickness, as seen in the vertical direction Z, is varied for a given width Ly. In this example, the variation of the thickness is varied in step-wise fashion. However, 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.

[0120] Analogously, as shown in FIG. 1b, the thickness, as seen in the vertical direction Z, is varied for a given length Lx. In this example, the variation of the thickness is varied in step-wise fashion. However, 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.

[0121] In some design options, as shown in various figures herein, 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.

[0122] According to one example embodiment, the shape of the transverse cross section is varied for a given length along the longitudinal direction X.

[0123] Turning again to e.g. FIGS. 1, 1a and 1b, 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.

[0124] Typically, although not strictly required, the pattern comprises at least one indentation and at least one projecting region.

[0125] According to one example embodiment, 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.

[0126] By way of example, 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.

[0127] According to one example embodiment, 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.

[0128] In addition, or alternatively, 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.

[0129] As illustrated in the various figures herein, the variation in thickness can also be varied in both the transverse direction Y and the longitudinal direction X.

[0130] In the following description in conjunction with the 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, 1a and 1b above.

[0131] FIG. 2A shows an example of an optimized bumper beam seen from the top with front (14), back (13) and optimized top (4) visible.

[0132] 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.

[0133] FIG. 3A shows a side bumper beam with optimized segments (4), front (14) and back (13).

[0134] 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.

[0135] FIG. 4A shows the unstressed bumper beam (6) FIG. 4B shows the bumper beam exposed to the load (4F) 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.

[0136] FIG. 5 shows the same collision simulation in FIG. 4b 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.

[0137] 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).

[0138] 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).

[0139] 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.

[0140] 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. With Enhancement pattern that one achieves through the patterns given by hollows in the rotating dies body (210B 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.

[0141] FIG. 9 shows an example of a beam segment that is reminiscent of an old classic so-called latticework, which usually is made by punching, milling, water cutting, or assembly of separate parts to high cost. By instead calculating the ideal the cross section of each segment (23A, 23B, 23C, 23D, 23E) and let the cross section of each segment vary as load varies from the points where they meet (23A, 23D) to their center (23B, 23E) to optimize the beam segment and beams, is achieved in a single step, a very weight optimised segment in a single process step. If you choose to do simple beam segment according to FIG. 9 it is possible to merge multiple identical or different segments to complete a square, triangular or other shape of the profile. The segment is also very appropriate to make a light and strong waist for the I-beam.

[0142] When joining multiple segments, 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. Through additionally process removing material (24) which is not maximum effective for segment strength, you can at an extra cost achieve further improved strength/weight ratio of beams and segments that don't need to be covered. 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.

[0143] To succeed with an extruded or pultruded so called truss segment or truss profile, you should take attention to creating a cross-sectional area (here exemplified with cut marks 25A, 25B, 25C and 25D) transverse profile that is substantially the same in pattern cycle (one revolution of the rotating shaping device/die) so that the profile strive to get out of uniform speed of extrusion/pultrusion tool. If the variations on outgoing cross-sectional area big and quickly arise a pulsation in a metal extrusion line could mean that every billet FIG. 201 (204) does not means a load cycle for the extrusion line, but several hundred load cycles, which would soon lead to fatigue. Moreover, it would be very difficult to get good a quality profile.

[0144] That is why it advisable to if 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). Then, when 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.

[0145] 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. FIG. 10. 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).

[0146] In FIG. 10 A-A you can clearly see how the pattern vary thickness and how to use it.

[0147] In 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).

[0148] In FIG. 11 is shown how one can vary the thickness on an optimized profile (28), by varying the rotating die position, relatively static bearings.

[0149] In 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).

[0150] 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.

[0151] This provides a profile which has very special properties: it is flexible and weak to bending, while being very stiff and resistant to compression crosswise.

[0152] In 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 A1, A2, and A3 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.

[0153] In FIG. 15 is shown how to vary the cross-sectional and pattern along an imaginary product (35), to be different properties at different locations.

[0154] 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).

[0155] FIG. 202A+202B shows how the device and method interact to provide a stable start-up:

[0156] FIG. 202A shows the puller device is ready for process starting with gripping & steering puller (230A) inside the die between the rotating dies (210A), ready to grip, steer and pull outgoing material before it may deviates and cause process breakdown.

[0157] FIG. 202B shows how the gripping & steering puller (230B) has gripped the profile and pulls it in the desired direction, while rotating dies (10B) has gone into production mode and started designing outgoing material before it can deviate and cause process breakdown. In order to be able to produce several of those in the preceding preferred profiles with thin materials, patterns and/or varying thickness, it is generally necessary to do it according to 202A+202B to manage start up.

[0158] In order to obtain optimal material performance and as little scrapping as possible, it is advisable to avoid stopping for a re gripping of profile, this is achieved according to FIG. 204 A-B-C:

[0159] FIG. 204A shows how the gripping & steering puller (230A) 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 (14a) and ordinary gripping device (13a) can do it.

[0160] FIG. 204B shows how the gripping & steering puller (30B) has grabbed and takes the output material and goes through ordinary gripping device (213b) so that ordinary puller (14a) is able to take over when outgoing material reached regular grippers/puller.

[0161] FIG. 204C shows how the gripping puller has pulled out outgoing materials to the ordinary gripping device 213C which thereby able to grip the profile which can thus stretched-controlled by ordinary puller (214c) start pulling in the outbound profilewithout manual intervention, stop interruptions or risk for process breakdown caused by deviating outgoing material.

[0162] Gripper-puller (230C) 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.

[0163] FIG. 301 shows optimized profile (322) with pattern on inside, made by rotating dies (310), sitting in the core portion of the tool. By using movable bearing (318) enabling further opportunities to optimize the thickness and pattern. One can also see how the combination of half-lowered bearing (318b) and completely raised rotating die (304b) results in a hollow section with the patterned inside and smooth outer surface (22c) thereof 318b+304b=322c.

[0164] FIG. 302 shows how to produce optimized profiles with varied patterns by varying the position of rotary dies (4a, 4b) relative to the adjustable bearing (18b).

[0165] FIG. 303 shows how to vary the thickness and pattern (322a, 322b, 322c) at extrusion of hollow section (322) by varying the position of rotary dies (4a,4b, 4c) and adjustable bearings (18a, 18b). This can of course, also be carried out during extrusion of non-hollow sections.

[0166] FIG. 304 shows a third embodiment of the invention where varying the thickness of the outgoing profiles, by varying the bearings (313) position.

[0167] FIGS. 304a and 304b shows the relationship between the bearings length (314a, 314b) and profile thickness (315a, 315b) kept reasonably constant at varied thickness, by allowing static bearing surface in fixed tool part cooperating with the bearings variable bearing lengthwhich is important to get the balance flow and stable process.

[0168] By the thickness varied over profile/beam segments length, regardless of the rotating shaping cycle entities (which consist of a rotation), so you get maximum strength on the part of beam/the profile which is subjected to the greatest loads.

[0169] This is achieved by 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. In this way one can ensure that 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.

[0170] The disclosure also covers all conceivable combinations of the described aspects, variants, alternatives and example embodiments of the disclosure.

[0171] Furthermore, the disclosure is not limited to the aforesaid aspects or examples, but is naturally applicable to other aspects and example embodiments within the scope of the following claims.