U.S. patent application number 11/175485 was filed with the patent office on 2006-01-12 for reinforced structural member and method for its manufacture.
Invention is credited to Jeffrey Bladow, Edward Engler, Jim Zimmerman.
Application Number | 20060005503 11/175485 |
Document ID | / |
Family ID | 35539858 |
Filed Date | 2006-01-12 |
United States Patent
Application |
20060005503 |
Kind Code |
A1 |
Bladow; Jeffrey ; et
al. |
January 12, 2006 |
Reinforced structural member and method for its manufacture
Abstract
A structural member for the body of a motor vehicle includes a
generally elongated support member which at least partially
encloses an interior volume, and a reinforcing insert which is
disposed in the interior volume. The reinforcing insert extends
along at least a portion of the length of the support member, and
has a cross section which defines a closed perimeter that encloses
an area. The insert member may be configured so as to control its
deformation characteristics thereby providing a structural member
which efficiently and safely absorbs kinetic energy in a crash.
Inventors: |
Bladow; Jeffrey; (West
Bloomfield, MI) ; Zimmerman; Jim; (Grosse Ile,
MI) ; Engler; Edward; (Farmington Hills, MI) |
Correspondence
Address: |
GIFFORD, KRASS, GROH, SPRINKLE & CITKOWSKI, P.C
PO BOX 7021
TROY
MI
48007-7021
US
|
Family ID: |
35539858 |
Appl. No.: |
11/175485 |
Filed: |
July 6, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60588118 |
Jul 14, 2004 |
|
|
|
60586009 |
Jul 7, 2004 |
|
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|
Current U.S.
Class: |
156/130.7 |
Current CPC
Class: |
B62D 25/04 20130101;
E04C 3/28 20130101; B62D 21/15 20130101; E04C 2003/0413 20130101;
E04C 2003/043 20130101; E04C 2003/0465 20130101; E04C 3/07
20130101 |
Class at
Publication: |
052/735.1 |
International
Class: |
E04C 3/30 20060101
E04C003/30 |
Claims
1. A structural member for a body of a motor vehicle, said
structural member comprising: a generally elongated support member
which at least partially encloses an interior volume; and a
reinforcing insert which is disposed within said interior volume
and which extends along at least a portion of the length of said
support member, said reinforcing insert having a cross section
which defines a closed perimeter that encloses an area.
2. The member of claim 1, wherein said cross section of said
reinforcing insert is a trapezoidal cross section.
3. The member of claim 1, wherein said reinforcing insert is bonded
to an interior surface of said support member.
4. The member of claim 3, wherein said reinforcing insert is
adhesively bonded to said interior surface.
5. The member of claim 1, wherein said reinforcing insert has a
cross section which defines two spaced-apart portions, said
spaced-apart portions being joined together by a connecting
portion.
6. The member of claim 5, wherein said spaced-apart portions each
comprise a lobe, each lobe having a cross section which defines a
perimeter that encloses a separate, respective area.
7. The member of claim 6, wherein at least one of said lobes has a
trapezoidal cross section.
8. The member of claim 5, wherein said connecting portion does not
have a cross section which defines a perimeter that encloses a
respective area.
9. The member of claim 6, wherein said connecting portion has a
cross section which defines a perimeter that encloses a separate
respective area.
10. The member of claim 1, wherein at least one of said support
member and said reinforcing insert are made of steel.
11. The member of claim 1, wherein at least one of said support
member and said reinforcing insert are made of roll-formed
steel.
12. A method of making a structural member for a body of a motor
vehicle, said method comprising the steps of: providing a generally
elongated support member which at least partially encloses an
interior volume; providing a reinforcing insert having a cross
section which defines a closed perimeter that encloses an area; and
disposing said reinforcing insert in said interior volume so that
said reinforcing insert extends along at least a portion of the
length of said support member.
13. The method of claim 12 including the step of carrying out a
further processing operation on said support member after said
reinforcing insert is disposed therein.
14. The method of claim 13, wherein said further processing
operation is selected from the group consisting of: roll forming,
sweeping, twisting, bending, die forming, cutting, drilling,
flattening, crushing, heating, welding, brazing, quenching, and
combinations thereof.
15. The method of claim 12, wherein said reinforcing insert is
subjected to a processing operation before being inserted into said
support member.
16. The method of claim 12, wherein at least one of said support
member and said reinforcing insert are roll formed.
17. The method of claim 12, wherein at least one of said support
member and reinforcing insert are made of steel.
18. The method of claim 12, including the further step of bonding
said reinforcing insert to said support member.
19. The method of claim 18, wherein said step of bonding comprises
adhesively bonding said reinforcing insert to said support
member.
20. The method of claim 12, wherein said reinforcing insert has a
cross section which defines two spaced-apart lobes, said lobes
being joined together by a connecting portion.
21. The method of claim 12, wherein said cross section of said
reinforcing insert defines a trapezoidal perimeter.
22. A motor vehicle body which includes the structural member of
claim 1.
Description
RELATED APPLICATIONS
[0001] This application claims priority of U.S. Provisional Patent
Application Ser. No. 60/588,118 filed Jul. 14, 2004, entitled
"Reinforcement for a B-Pillar of an Automotive Vehicle" and U.S.
Provisional Patent Application Ser. No. 60/586,009 filed Jul. 7,
2004 and entitled "Method of Inserting Structural Member in a
Roll-Formed Part."
FIELD OF THE INVENTION
[0002] This invention relates generally to reinforced structures.
More particularly, the invention relates to reinforced structures
used in motor vehicles. In particular, the invention relates to
lightweight reinforced structures which can be used as support
pillars, frame members and the like for motor vehicles.
BACKGROUND OF THE INVENTION
[0003] Many motor vehicles have a passenger compartment or cargo
space which is defined and supported by a framework comprised of a
plurality of pillars or other such support members. The support
members provide structural integrity to the body of the motor
vehicle and serve to protect the occupants or cargo in the event of
a crash. In some instances, the support members are configured so
as to deform in a controlled manner and thereby absorb kinetic
energy in the event of a crash.
[0004] Pillars comprising the support framework of a motor vehicle
are generally configured as hollow steel bodies. Preferably, the
support members combine high strength and low weight. Also, the
pillars should be low in cost with regard to both materials and
their process for fabrication. Ideally, any such support structure
should also be amenable to being manufactured by high speed forming
processes such as roll forming, cold stamping and the like.
[0005] In early prior art, pillar structures for motor vehicles
were typically comprised of simple, hollow, tubular members.
Eventually various reinforcing members were included in such
structures. In some instances, reinforcing members are disposed on
the outside of a hollow pillar, and one such structure is shown in
U.S. Pat. No. 5,833,303. In other instances, reinforcing members
were disposed, at least partially, internally of pillars and other
structural members. Some such reinforced structures are shown in
U.S. Pat. Nos. 6,341,467; 3,779,595 and 6,883,858.
[0006] The motor vehicle industry is directed toward increasing
safety and fuel efficiency of vehicles while keeping costs at a
minimum. Hence, there are concurrent needs for decreasing the
weight and increasing the strength of the passenger and/or cargo
compartments of motor vehicles. Toward that end, the industry is
seeking structural components for motor vehicles which combine
light weight and high strength; furthermore, such components should
be capable of having their deformation characteristics tuned or
controlled so as to maximize the absorption of kinetic energy while
maintaining sufficient integrity to prevent injuries to passengers
or damage to cargo in the event of a crash. As will be explained in
detail hereinbelow, the present invention is directed to reinforced
structural members which may be incorporated into bodies of motor
vehicles. The structural members of the present invention are light
in weight, inexpensive to fabricate, and can be configured to
provide controlled deformation properties. These and other
advantages of the invention will be apparent from the drawings,
discussion and description which follow.
BRIEF DESCRIPTION OF THE INVENTION
[0007] Disclosed herein is a structural member of the type which
may comprise a support member for the body of a motor vehicle. The
structural member comprises a generally elongated pillar or other
such support member which at least partially encloses an interior
volume, and a reinforcing insert which is disposed within the
interior volume and which extends along at least a portion of the
length of the support member. The reinforcing insert has a cross
section which defines a closed perimeter that encloses an area. In
some instances, the reinforcing insert is bonded to the interior
surface of the support member, such as by means of an adhesive or
mechanical interconnection. In particular embodiments, the
reinforcing insert has a cross section which defines two
spaced-apart portions which are joined together by a connecting
portion. In specific configurations of this embodiment, the
spaced-apart portions each comprise a lobe, each lobe having a
cross section which defines a perimeter that encloses a separate,
respective area. In some instances, the connecting portion may also
have a perimeter which defines and encloses a respective area;
while in other instances, the connecting portion may be otherwise
configured.
[0008] In some instances, the support member and/or the reinforcing
insert may be made of steel.
[0009] Also disclosed herein is a method for making the structural
member, as well as the use of the structural member in a motor
vehicle body.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a cross-sectional, perspective view of one
embodiment of structural member of the present invention;
[0011] FIGS. 2-5 are cross-sectional views of other embodiments of
reinforcing inserts which may be utilized in the practice of the
present invention;
[0012] FIG. 6 is a cross-sectional view of another reinforcing
insert of the present invention, inserted into a support member;
and
[0013] FIG. 7 is a cross-sectional view of the insert of FIG. 6,
which is shown disposed in another configuration of support
member.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The present invention is directed to structural members
which may be used for the fabrication of high strength, lightweight
frameworks and other support structures. The present invention has
particular utility in a support member for the body of a motor
vehicle, and will be explained with particular reference to that
utility. However, it is to be understood that the present invention
may be employed in connection with other structures such as static
building structures, protective cages, intrusion barriers, and
other constructions wherein high strength, light weight, and
controlled deformation characteristics are required.
[0015] The structural member of the present invention includes a
generally elongated support member which at least partially
encloses an interior volume. As such, the support member's
structure may comprise a hollow tubular type of member formed from
a single body of material or from plural bodies joined together. In
other instances, the support member may be partially open, and as
such may have a C-shaped profile. The reinforcing insert is
disposed in the interior of the pillar so as to extend along at
least a portion of its length. In some instances, the reinforcing
insert will extend along the entire length of the pillar, and in
other instances it may extend along only a portion of the length of
the pillar, while in yet other instances a plurality of separate
insert members may be disposed in a support member. The reinforcing
insert has a cross-sectional profile which defines at least one
closed perimeter bounding an area. As will be explained in detail
hereinbelow, in some instances, the insert may bound a plurality of
internal areas. The insert increases the strength of the support
member, particularly with regard to side loading and/or buckling.
The cross-sectional profile of the insert may be controlled so as
to control the deformation characteristics of the structural member
in which it is incorporated.
[0016] Various configurations and embodiments of the present
invention may be implemented. Referring now to FIG. 1, there is
shown one embodiment of structural member 10 configured in accord
with the present invention. The structural member 10 of FIG. 1
comprises a support member 12 which is configured as a hollow,
pillar member which encloses an interior volume. As was explained
hereinabove, in other embodiments, the support member may only
partially enclose an interior volume. The member 12 in this
embodiment is comprised of two separate hat-shaped portions 14, 16
which are joined together along their edges so as to form a pair of
flanges 18, 20. The two portions 14, 16 may be joined together by
welding, adhesives, or by mechanical means such as rivets, toggles,
piercings, tabs or the like. In some instances, the support member
may be fabricated from a single piece of material folded back onto
itself or from a tube. The support member, in particular instances,
is fabricated from a metal such as sheet steel, and may be
manufactured by conventional forming processes such as hot
stamping, cold stamping, roll forming, drawing, pressing or the
like. In other instances, the support member may be fabricated from
polymeric materials or composites utilizing well-known techniques
including casting, molding extrusion and the like.
[0017] Disposed within the interior volume of the support member 12
is a reinforcing insert 22. In the FIG. 1 embodiment, the
reinforcing insert 22 includes a first lobe portion 24 and a second
lobe portion 26 joined together by a connecting portion 28. In the
illustrated embodiment, the two lobe portions 24, 26 each have a
cross section of trapezoidal configuration which encloses a
respective interior volume. It has been found, in particular
embodiments of the present invention, that a trapezoidal cross
section is advantageously employed in at least portions of
reinforcing inserts of the present invention. An insert with a
trapezoidal portion provides high strength and good resistance to
crushing when subjected to a side impact. This is in contrast to
square-sided structures which tend to collapse in a failure mode
akin to the collapse of a side-loaded matchbox; hence, this failure
mode is referred to in the art as "matchboxing."
[0018] In the illustrated embodiment, the two lobe portions 24, 26
of the insert 22 are joined together by a connector portion 28
which is a simple straight wall structure. As will be detailed
hereinbelow, other configurations of insert may be employed in the
practice of the present invention.
[0019] As shown herein, a back wall portion 30 of the first lobe
24, and a back wall portion 32 of the second lobe 26 are
corrugated. One function of these corrugations is to hold an
adhesive material therein. For example, a heat activatable,
foamable adhesive may be disposed in the corrugations of the insert
22 of FIG. 1. The recessed portions of the corrugation will allow
the insert to be stored, handled and subsequently disposed within
the support member 12 without causing unwanted transfer of
adhesive; however, when the resulting combination is subsequently
heated, as for example during painting or further processing steps,
the adhesive will foam, expand, and fill the space between the
insert 22 and inner surfaces of the support member 12. The adhesive
will assure that the insert remains in place in the support member
without shifting or rattling. The feature of the corrugations
and/or the adhesive is optional, and it is to be understood that
the profiles of the lobes as illustrated in FIG. 1 are to be
considered trapezoidal even though there is some corrugation of the
surfaces of the lobes.
[0020] Support members such as the pillar shown in FIG. 1 may be
fabricated as relatively long members which are subsequently cut to
length for use in particular applications, or they may be
fabricated to approximate finished dimensions. Also, while the FIG.
1 embodiment shows a generally linearly elongated structural
member, it is to be understood that the present invention may be
readily adapted to the manufacture of components having a curved or
other complex geometry.
[0021] The support member may be formed to a finished profile and
then have the insert placed therein, for example as by threading it
through an open end. Or, the support member may be partially
fabricated, the insert disposed therein, and the structure then
completed so as to enclose the insert. In specific instances, the
insert is fabricated from high strength, relatively thin steel,
such as a hardenable steel. Both the support member and insert may
be fabricated from relatively thin steel stock which can be bent to
radii as low as one thickness of the stock material, so as to crowd
the profile mass to the outermost tension and compression sides of
the structure. In specific embodiments, the components are made out
of a material such as aluminum, steel, or aluminized steel having a
strength of over 100 ksi. In specific instances, the thickness of
the reinforcing member is between 0.5 mm and 2.0 mm, and in yet
other instances, the distribution of material between the first 24
and second 26 lobes is approximately 60% and 40% respectively.
[0022] The completed structural member may be subjected to further
post-fabrication processing and this can involve shaping operations
such as roll forming, sweeping, bending, die forming, cutting,
drilling, flattening, crushing and the like which change its shape
or profile. Likewise, the individual support member and/or
reinforcing insert may be subject to such processing steps prior to
assembly. Other operations may comprise heating, quenching,
welding, brazing, cutting, piercing and the like. For example, the
member may be bent, swept, or twisted to form a component such as
bumper bar or side intrusion beam for a motor vehicle. In that
regard, the member may be heat treated so as to increase its
hardness.
[0023] Other configurations of reinforcing insert may be utilized
in the present invention. For example, FIG. 2 shows an insert 40
which comprises a body having a closed cross-sectional profile with
an upper portion 42, and a lower portion 44 joined by an
intermediate portion 46. All of the portions are contiguous so as
to bound a single internal space. As in the previous embodiment,
surfaces 48, 50 are corrugated; although, it is to be understood
that flat surfaces, concave surfaces, convex surfaces or the like
may be likewise employed. It will be appreciated that by varying
the dimensions L and D of the intermediate portion 46, crushing and
bending characteristics of the insert 40 may be adjusted.
[0024] FIG. 3 illustrates another embodiment of insert 52. This
insert 52 is generally similar to the insert 22 of FIG. 1 insofar
as it includes an upper lobe portion 54 and a lower lobe portion
56, both of which have a generally trapezoidal cross section. As in
the FIG. 1 embodiment, the two lobe portions 54 and 56 are joined
by a connecting portion 58; however, this connecting portion is of
an open configuration, and in that regard also bounds an interior
space. The open, diamond-shaped configuration of the connecting
portion 58 allows for controlled crushing and/or bending of the
insert 52. It will be appreciated that this intermediate portion 58
may be otherwise configured; for example, it may comprise a member
having a circular cross section as well as otherwise configured
polygonal cross sections.
[0025] FIG. 4 shows yet another configuration of insert 60 which is
configured to have a simple, trapezoidal cross section. As
illustrated, this member includes corrugated surfaces 62 and 64;
this feature is, as noted above, optional and the surfaces may be
otherwise configured.
[0026] FIG. 5 shows yet another embodiment of insert 70. This
insert 70 is of generally trapezoidal configuration, and in that
regard is somewhat similar to the insert 60 of FIG. 4. However, in
this embodiment, an upper lobe 72 and a lower lobe 74 are
interconnected by two S-shaped portions 76 and 78. Under a
predetermined load on the insert 70, the S-shaped portions 76, 78
will plastically deform to allow the sidewalls 80, 82 of the first
lobe portion 72 to collapse in a telescoping manner about the
sidewalls 84, 86 of the second lobe portion 74. In other versions
of this embodiment, further S-shaped portions may be incorporated.
Alternatively, corrugations may be disposed to serve a similar
function.
[0027] In yet other embodiments of insert, selected deformation may
be accomplished by cutting, piercing, or otherwise physically
interrupting selected wall portions of the insert. Also, it is to
be understood that while the foregoing has primarily described the
inserts as being fabricated from metals, polymeric materials,
including foamed polymeric materials as well as polymer/metal
composites, may be employed to form the insert member.
[0028] Referring now to FIGS. 6 and 7, there is shown another
embodiment of reinforcing insert 90 structured in accord with the
principles of the present invention. In both illustrations, the
insert 90 has a cross section which defines a closed perimeter that
encloses an interior area. The insert 90 further includes
projecting flanges 92 and 94. As illustrated, the insert 90 is
formed from a single piece of material folded back on itself;
although, it is to be understood that it could be fabricated as a
two-part member. In the FIG. 6 embodiment, the insert 90 is
disposed within a support member 96 which comprises a tubular
member having a generally square cross section. As shown in FIG. 6,
the insert 90 is placed diagonally in the support member 96 so that
the flanges 92 and 94 engage corners thereof. It is to be
understood that other embodiments of flanged insert having a
different cross-sectional profile, such as a trapezoidal profile, a
circular profile and the like, could be similarly disposed.
[0029] Referring now to FIG. 7, there is shown the insert 90 as
disposed in a support member 98. The support member 98 includes
flange portions 100, 102 which engage the flanges 92 and 94 of the
insert member 90. In this embodiment, the insert and support member
may be secured by tack welds, adhesive, mechanical interlocks,
crimps or the like. Yet other configurations of support member and
insert may likewise be configured.
[0030] Support members of various other configurations may also be
employed in the practice of the present invention. Such members may
include fully and partially closed structures, curved structures,
straight structures, and structures of complex shapes. Also, while
the support members are primarily described herein as being made of
steel, it is to be understood that support members of other
materials including metals and synthetic polymers may be
utilized.
[0031] In view of the teaching presented herein, still further
modifications, variations and embodiments of the present invention
will be apparent to those of skill in the art. The foregoing
drawings, discussion and description are illustrative of only
specific embodiments, and are not meant to be limitations upon the
practice of the invention. It is the following claims, including
all equivalents, which define the scope of the invention.
* * * * *