Method and device for producing an energy-absorbing profile for a motor vehicle

Abstract

A method for producing an energy-absorbing profile for a motor vehicle includes: providing an extruded hollow profile, the extruded hollow profile having outer walls and at least one inner wall which connects two of the outer walls; inserting a cutting tool into the hollow profile; actuating the cutting tool and cutting an inner wall section out of the inner wall; and removing the cut out wall section and the cutting tool from the hollow profile.

Claims

1. A method for producing an energy-absorbing profile for a motor vehicle comprising: extruding a deformable energy-absorbing material, said extruded material having outer walls and at least one inner wall which connects two of the outer walls; inserting a cutting tool into a hollow profile; actuating the cutting tool and cutting 20% to 80% of an inner wall section out of the inner wall; and removing the cut out wall section and the cutting tool from the hollow profile.

2. The method of claim 1, wherein adjacent regions of the at least one inner wall are supported during the cutting.

3. The method of claim 1, wherein the cutting tool has a first cutting tool part and a second cutting tool part and the first cutting tool part is inserted from an end side of the hollow profile into a first chamber of the hollow profile on a first side of the inner wall and the second cutting tool part is inserted from another end side of the hollow profile into a second chamber of the hollow profile on a second side of the inner wall opposite to the first side.

4. The method of claim 1, wherein the cutting tool is actuated by drive means, which act outside of the hollow profile.

5. The method of claim 1, wherein the cutting tool is actuated by drive means, which act within the hollow profile.

6. A device constructed for carrying out the method of claim 1, said device comprising a cutting tool which extends through a length of the hollow profile, said cutting tool having blades, said blades being arranged so as to enable cutting out an inner wall section of the inner wall of the hollow profile by actuation of the cutting tool.

7. The device of claim 6, further comprising drive means for actuating the cutting tool, said drive means acting from an outside of the hollow profile and/or within the hollow profile upon the cutting tool or on the cutting tool.

8. The device of claim 6, wherein the cutting tool comprises two cutting tool parts constructed for insertion into the hollow profile in a same direction or in opposite directions.

9. The device of claim 6, further comprising an outer support unit which receives the hollow profile.

10. A device for producing an energy-absorbing profile comprising an extruded deformable energy-absorbing material for a motor vehicle with outer walls and at least one inner wall which connects two of the outer walls, said inner wall being removed in an inner wall section at least in regions, said device comprising: a cutting tool which extends through a length of the hollow profile, said cutting tool having blades which are arranged so as to effect cutting 20% to 80% out of an inner wall section of the inner wall of a hollow profile by actuation of the cutting tool.

11. The device of claim 10, further comprising drive means for actuating the cutting tool, said drive means acting from an outside of the hollow profile and/or within the hollow profile upon the cutting tool or on the cutting tool.

12. The device of claim 10, wherein the cutting tool comprises two cutting tool parts constructed for insertion into the hollow profile in a same direction or in opposite directions.

13. The device of claim 10, further comprising an outer support unit which receives the hollow profile.

Description

BRIEF DESCRIPTION OF THE DRAWING

(1) In the following, the invention is described by way of drawings. It is shown in:

(2) FIG. 1 an energy-absorbing profile in a perspective view;

(3) FIG. 2 the energy-absorbing profile according to FIG. 12 with view into the inner space;

(4) FIG. 3 a schematic side view of a representation of the starting profile of an energy-absorbing profile;

(5) FIG. 4 the hollow profile of an energy-absorbing profile together with a first cutting tool;

(6) FIG. 5 the hollow profile of an energy-absorbing profile together with a second embodiment of a cutting tool.

(7) FIG. 6 the hollow profile of an energy-absorbing profile together with a further embodiment of a cutting tool;

(8) FIG. 7 the hollow profile of an energy-absorbing profile together with a further embodiment of a cutting tool;

(9) FIG. 8 the hollow profile of an energy-absorbing profile together with a further embodiment of a cutting tool;

(10) FIG. 9 the hollow profile of an energy-absorbing profile together with a further embodiment of a cutting tool;

(11) FIG. 10 a front view onto a hollow profile of an energy-absorbing profile together with a cutting tool in vertical cross section and

(12) FIG. 11 a front view onto the hollow profile of an energy-absorbing profile and an embodiment of a device for producing the energy-absorbing profile.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

(13) FIGS. 1 and 2 show an energy-absorbing profile 1 produced according to the invention. The energy-absorbing profile 1 has an extruded hollow profile 2 made of light metal or a light metal alloy. The hollow profile 2 has a circumferentially closed rectangular cross section, which has four outer walls 3, 4, 5, 6. In the here shown exemplary embodiment, three inner walls 7, 8, 9 extend between the two lateral outer walls 4, 6. The inner walls 7, 8, 9 connect the lateral outer walls 4, 6 and divide the hollow profile 2 into a total of four chambers 10, 11, 12, 13 (see also FIG. 3). The inner walls 7, 8, 9 extend in longitudinal direction L of the hollow profile 2. The inner walls 7, 8, 9 are arranged above each other at a distance a. The distance a between the inner walls 7, 8, 9 can vary. In the outer walls 3, 4, 5, 6 longitudinal embossments 14 and transverse embossments 15 are provided. In addition, holders 16, mounting elements 17 and mounting openings 18 are provided in the hollow profile of the energy-absorbing profile 1.

(14) FIG. 2 provides insight into the internal space of the hollow profile 2. For this, the lateral outer wall 6 is shown partially opened. It can be seen that the inner walls 7 and 9 are removed in an inner wall section 19, 20. As a result recesses 21, 22 are formed in the inner walls 7, 9. The recessed or removed wall sections 19, 20 are situated in the center longitudinal region of the hollow profile 2. The inner walls 7, 9 extend respectively on the right hand and left hand side of the removed wall sections 19, 20 up to the end sides 23 of the hollow profile 2 which are located on the left hand and right hand side in the image plane.

(15) In the here shown exemplary embodiment, the removed wall section 19 is located in the inner wall 7 or the recess 21 and the removed wall section 20 in the inner wall 9 or the recess 22 so as to be aligned with each other.

(16) The recesses 21, 22 in the inner walls 7, 8, 9 formed by the removed wall sections 19, 20 can also be arranged offset to each other. The recesses 21, 22 in the inner walls 7, 8, 9 can also vary from each other regarding their size and configuration.

(17) By removing the inner wall sections 19, 20 in the inner walls 7, 9 the stiffness properties and in particular the deformation properties and with the energy-absorbing capacity of the energy-absorbing profile 1 can be adjusted. In particular the appropriate choice of the removed wall sections 19, 20 and their geometry allows influencing the deformation properties and the fold formation characteristic in the case of exposure to load and exceedance of a defined load level. In this context the removed wall sections 19, 20 can be removed flush relative to the inner surface of the outer walls 4, 6. Also, webs can remain along the outer walls 4, 6 in order to define the deformation properties.

(18) FIGS. 3 to 9 show different embodiments of the cutting tools of a device for producing an energy-absorbing profile 1 according to the invention, each in a schematic side view. For reasons of clarity the cutting tool is shown in FIGS. 3 to 9 in open position.

(19) FIGS. 10 and 11 show side views onto a hollow profile 2 of an energy-absorbing profile 1 with illustration of different cutting tools.

(20) FIG. 3 schematically shows a side view of an extruded hollow profile 2 corresponding to the configuration according to FIGS. 1 and 2 prior to the removal of inner wall sections. The hollow profile 2 shown in FIG. 3 serves as starting profile for the production of the energy-absorbing profile 1 according to the invention and is cut to size from a light metal profile strand. Subsequently a cutting tool 24 or cutting tool parts 25, 26 are inserted into the hollow profile 2 and an internal wall section 19, 20 or 27 is cut out form one or multiple of the inner walls 7, 8, 9. Subsequent thereto the cut out wall section 19, 20 or 27 and the cutting tool 24 are removed from the hollow profile.

(21) The cutting out or separating out of the wall sections 19, 20, 27 can be carried out with a variety of devices with different cutting tools.

(22) In the device shown in FIG. 4, a cutting tool 24 is used which includes two cutting tool parts 25, 26 which extend over the length of the hollow profile 2 so that lateral ends 28, 29 of the cutting tool parts 25, 26 protrude relative to the hollow profile 2. The upper first cutting tool 25 acts as punch die and has a blade 30. The lower second cutting tool part 26 has a female die 31, which is complementary to the blade 30 and severs at the same time as counter holder. Laterally to the blade 30 and the female die 31, support zones 32, 33 are respective provided which during the separation process come into contact with the inner wall 7, 8, 9 and support the inner wall 7, 8, 9 (in the here shown exemplary embodiment the inner wall 8) during the separation process. The cutting tool 24 is actuated by drive means 34 which are located outside the hollow profile 2 and act on the cutting tool parts 25, 26. The drive means 34 are illustrated by the arrows. By actuating the cutting tools 24 an inner wall section 27 of the inner wall 8 of the hollow profile 2 is cut out.

(23) The device as shown in FIG. 5 includes a cutting tool 35 with an upper first cutting tool part 36 and a lower second cutting tool part 37 which interact with each other in order to remove an inner wall section 19 of the upper inner wall 7. The cutting tool 35 is actuated by drive means 38, which act inside the hollow profile 2. These are a press die 39 which acts through a through passage 40 in the upper outer wall 3 of the hollow profile upon the first cutting tool part 36 and actuates the cutting tool 35.

(24) Also in this illustration the cutting tool parts 36, 37 are shown in the open position. During the cutting or separation process the cutting tool parts 36, 37 rest against the inner wall 7 to be processed and support the remaining regions or wall sections with support zones 41, while the central inner wall section 19 is cut out by the blade 42.

(25) The cutting tool 43 shown in FIG. 6 includes an upper first cutting tool part 44 and a lower second cutting tool part 45. The first cutting tool part 44 and the second cutting tool part 45 have a number of wedge-shaped blades 46 (saw teeth) which are configured to mutually match each other. The movement of the cutting tool parts 44, 45 toward each other to perform the cutting lift can occur mechanically by drive means 47 located outside the hollow profile 2.

(26) It is also possible that the blades are supported movable inside the cutting tool parts and can be actuated by appropriate drive means.

(27) In the cutting tool 48 of the device as can be seen in FIG. 7, the actuation of the cutting tool parts 49 50 occurs by at least one drive part 51 which acts inside the hollow profile 2. The drive means 51 is formed by a hydraulically or pneumatically expandable body 52, for example a tubular body. The expansion capability of the body 52 is indicated by the arrows P. As a result of expansion of the tubular body 52, the first cutting tool part 49 is moved and the separation process effected. Hereby an inner wall section 27 of the inner wall 8 is removed.

(28) The cutting tool 53 of the device as shown in FIG. 8 has an upper first cutting tool part 54 with an obliquely extending blade 55. The lower second cutting tool part 56 has a female die 57 with a recess 58, which has a configuration matching the one of blade 55. By closing the cutting tool 53, an inner wall section 27 of the inner wall 8 is cut out. The shearing force essentially acts in longitudinal direction L of the cutting tool 53 or the hollow profile 2.

(29) The cutting tool 59 of the device according to FIG. 9 has at the upper first cutting tool part 60 blades 61, which are slanted on the outside vertically and inside by a wedge angle in order to cut out the inner wall section 27. The lower second cutting tool part 62 has a female die 63, which has a configuration matching the blade 61. The shearing force acts in the direction toward the cutting tool 59 or the hollow profile 2.

(30) The device shown in FIG. 10 includes a cutting tool 64 with an upper first cutting tool part 65 and a lower second cutting tool part 66 which are introduced into the hollow profile 2 from an end side. The first cutting tool part 65 has lateral blades 67 with vertical outer surfaces 68 and an inner wedge surface 69. The cutting tool 64 has a width, which is adjusted to the inner width b of the hollow profile 2. During the separation process the inner wall section 20 of the inner wall 9 is cut out flush along the inner surfaces 70 of the outer walls 4, 6.

(31) Above the first cutting tool part 65 a drive means 71 in the form of an expanding mandrel 72 is shown in a technically simplified manner.

(32) The device in the embodiment according to FIG. 11 has a cutting tool 73 with an upper first cutting tool part 74 and a lower second cutting tool part 75. The first cutting tool part 74 has blades 76 which interact with a die 77 in the lower second cutting tool part 75. As can be seen the cutting tool parts 74, 75 are adapted to each other and arranged so that an inner wall section 20 of the inner wall 9 of the hollow profile 2 is cut out by actuation of the cutting tool 73, wherein lateral webs 78, 79 remain standing in the inner wall 8 during the separation process.

(33) An outer support unit 80 of the device can also be seen. The support unit 80 has a receiving space 81 for the hollow profile 2. In the support unit 80 the hollow profile is held during the cutting process.