U.S. patent application number 14/203866 was filed with the patent office on 2014-07-10 for method of manufacturing a sturctural ultra-thin sheet metal part with patch welded reinforcements.
This patent application is currently assigned to Ford Global Technologies, LLC. The applicant listed for this patent is Ford Global Technologies, LLC. Invention is credited to Omar GHOUATI, Horst Heribert LANZERATH, Juergen WESEMANN.
Application Number | 20140193659 14/203866 |
Document ID | / |
Family ID | 47297148 |
Filed Date | 2014-07-10 |
United States Patent
Application |
20140193659 |
Kind Code |
A1 |
LANZERATH; Horst Heribert ;
et al. |
July 10, 2014 |
METHOD OF MANUFACTURING A STURCTURAL ULTRA-THIN SHEET METAL PART
WITH PATCH WELDED REINFORCEMENTS
Abstract
A sheet metal component for a vehicle comprising a metal sheet
having thickened portions integrated into the metal sheet that
reinforces local areas of the sheet metal component. The metal
sheet has integrally formed longitudinal members and cross-members.
A method of manufacturing a sheet metal component is also disclosed
that comprises selecting a planar sheet metal blank that is cut to
size to define an outer contour. At least one reinforcing layer is
provided on the blank to form thickened portions of the blank. The
method also includes the steps of heating the blank, forming the
blank into the desired geometric shape of the sheet metal
component, and hardening the sheet metal component.
Inventors: |
LANZERATH; Horst Heribert;
(Bad Muenstereifel, DE) ; GHOUATI; Omar; (Aachen,
DE) ; WESEMANN; Juergen; (Wuerselen, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ford Global Technologies, LLC |
Dearborn |
MI |
US |
|
|
Assignee: |
Ford Global Technologies,
LLC
Dearborn
MI
|
Family ID: |
47297148 |
Appl. No.: |
14/203866 |
Filed: |
March 11, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
PCT/EP2012/072674 |
Nov 15, 2012 |
|
|
|
14203866 |
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Current U.S.
Class: |
428/600 ;
72/364 |
Current CPC
Class: |
B62D 29/00 20130101;
B62D 25/20 20130101; B21D 31/00 20130101; B62D 25/2027 20130101;
Y10T 428/12389 20150115 |
Class at
Publication: |
428/600 ;
72/364 |
International
Class: |
B21D 31/00 20060101
B21D031/00 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 22, 2011 |
DE |
10 2011 086 813.5 |
Claims
1. A sheet metal component for a vehicle comprising: a metal sheet
having thickened portions integrated into the metal sheet that
reinforce local areas of the sheet metal component, wherein the
metal sheet has integrally formed longitudinal members and
cross-members.
2. The sheet metal component of claim 1 wherein the metal sheet is
selected from a group consisting essentially of: boron steel; FeMn
steel; FeAl steel; and aluminum alloy.
3. The sheet metal component of claim 1 wherein the metal sheet is
boron steel having a thickness of less than or equal to 0.7 mm.
4. The sheet metal component of claim 1 wherein the integrally
formed longitudinal members further comprise at least one U-shaped
channel formed in a longitudinal direction in the sheet metal
component.
5. The sheet metal component of claim 1 wherein the cross-members
further comprise at least one rib formed in a transverse direction
in the sheet metal component.
6. A method of manufacturing a sheet metal component comprising:
selecting a planar sheet metal blank that is cut to size defining
an outer contour; providing at least one reinforcing layer to the
blank to form thickened portions on the blank; heating the blank;
forming the blank into a geometric shape of the sheet metal
component; and hardening the sheet metal component.
7. The method of claim 6 wherein the step of providing at least one
reinforcing layer further comprises assembling small planar sheet
metal plates to the blank and welding the small planar sheet metal
plates to the blank.
8. The method of claim 6 wherein the step of providing at least one
reinforcing layer further comprises assembling small planar sheet
metal plates to the blank and pressing the small sheet metal plates
into the blank.
9. The method of claim 6 wherein the step of providing at least one
reinforcing layer further comprises rolling the reinforcing layer
onto the blank by varying a roll gap.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of PCT application Ser.
No. PCT/EP2012/072674 filed Nov. 15, 2012, which claims the benefit
of DE 10 2011 086 813.5 filed Nov. 22, 2011, the disclosures of
which are hereby incorporated by reference in their entirety.
TECHNICAL FIELD
[0002] This disclosure relates to a method of manufacturing sheet
metal parts for vehicles from a blank that has locally thickened
areas that are formed into integral reinforcements.
BACKGROUND
[0003] In commercially available motor vehicles, sheet metal
components having a large surface area may be reinforced by means
of rails and/or longitudinal members and cross-members to produce a
self-supporting assembly.
[0004] For example, a floor structure consisting of a front sheet
metal part and a rear sheet metal part for a motor vehicle is
disclosed in U.S. Pat. No. 5,102,187. The sheet metal parts are
provided with a plurality of reinforcing elements in the form of
supports that are positioned on and welded to the sheet metal body.
Welded components are produced that form the floor region of the
motor vehicle.
[0005] A similar structure is disclosed in European Patent No. EP 1
525 132 B1 that discloses a floor plate that is reinforced by means
of a longitudinal member and a laterally applied web plate.
[0006] A sheet metal component produced in one piece is disclosed
in U.S. Pat. No. 7,111,900 B2 that is utilized to perform a
load-bearing function. This component is, however, of exceptionally
complicated construction and has curved regions that are partially
provided with undercuts and are very difficult to produce.
[0007] This disclosure is directed to solving the above problems
and other problems as summarized below.
SUMMARY
[0008] The object of this disclosure is to provide a one-piece,
self-supporting sheet metal component for a motor vehicle that may
be easily produced, has a high degree of strength and forms a
relatively lightweight structure.
[0009] According to one aspect of this disclosure, the component is
exclusively configured as a sheet metal part made of high-strength
metal and is provided with stiffening portions and/or
reinforcements in the regions that are subjected to particularly
high loads. A high-strength sheet metal part having geometric
stiffness is used to manufacture sheet metal parts having a large
surface area and relatively low wall thickness. The sheet metal
parts are substantially more lightweight than the known components
and also have at least the same stability.
[0010] A plurality of load paths may be integrated in a single
component having a large surface area to permit more uniform
load.
[0011] The sheet metal blank used to manufacture the component is
produced from high-strength heat-formed boron steel. Boron steel
sheet metal plates may have a thickness of 0.7 mm or less.
Geometrically complex components for motor vehicles may be produced
from heat-formed boron steel to obtain a very high degree of
strength in the component. The advantages of using heat-formed
boron steel are considerable savings of weight and a reduction in
the number of parts resulting in a reduction in production
costs.
[0012] Alternatively, the sheet metal plates may be made from
high-strength aluminum alloys that may be heat-formed and
press-hardened. If the component is designed to be easily
cold-formed, the sheet metal plates may, for example, also consist
of ductile high-strength steels, such as for example FeMn steel,
FeAl steel or other high-grade steels.
[0013] According to one embodiment, a one-piece component is
provided that includes a sheet metal part that has thickened
portions forming stiffening portions or reinforcements in the
regions that are subjected to particularly high loads. The local
thickened portions may be produced using "patch weld technology."
The sheet metal part with patch welded portions is then
subsequently hot-formed. In this case, small planar sheet metal
plates are welded (for example by laser welding or spot welding)
onto the planar base plate made of boron steel, in the "soft" state
before the forming process. The small planar sheet metal plates are
heated together with the base plate to approximately 950.degree.
C., formed and hardened. The structural properties of the component
may be accurately adjusted by changing the small planar sheet metal
plates to accommodate the respective structural requirements.
[0014] Reinforcing layers made of high-strength material welded to
the sheet metal part may also be provided as stiffening portions or
reinforcements. The reinforcing layers are welded, pressed or
rolled onto the sheet metal part and are provided as thickened
portions. Alternatively, at least some of the reinforcing layers
may be formed as sheet metal plates having a flexible thickness
distribution (also known as "tailor rolled blanks") that have a
thickness and strength progression that is obtained by varying the
roll gap when the sheets are rolled.
[0015] Alternatively, reinforcing layers made of high-strength
material that has been pressed or rolled onto the sheet metal part
may also be provided as thickened portions.
[0016] The reinforcements of the sheet metal part may also be
obtained by local hardening, for example by means of a heat
process. This process may also be used in a targeted manner to
adapt to the requirements of different vehicle models.
[0017] The reinforcing regions may be integrally formed in the
sheet metal plate as U-shaped channels and/or ribs in the
longitudinal direction and/or transverse direction of the sheet
metal part. To achieve optimal stability, the U-shaped channels
and/or ribs may be provided with closure plates. It is possible to
adapt to the load requirements of different vehicle models by using
closure plates of different thickness or strength. A one-piece
floor plate may be produced for different vehicle models that are
adapted to different load requirements later in the production
process.
[0018] The U-shaped channels may also be reinforced with structural
foam or plastic parts to achieve optimal stability. The
reinforcements, stiffening portions, closure plates, structural
foams or plastic inserts may be adapted to the load requirements of
different vehicle models. Flexible regions may also be provided in
the component by varying the arrangement of the reinforcing
regions.
[0019] The one-piece sheet metal component may be used in motor
vehicle construction for different regions of the vehicle. The
floor plate may be provided with a plurality of integrated load
paths. Alternatively, it is also possible to make a component for
the front wall, the bulkhead, the side regions and roof regions of
a motor vehicle body. The stiffening portions, reinforcements, or
thickened portions of the floor plate may be selected to perform
the function of the longitudinal members or cross-members.
Considerable weight savings may be achieved in the floor structure
of the vehicle by subdividing the part in the longitudinal
direction or in the transverse direction into at least two parts,
for example, into a front floor plate, and a rear floor plate.
[0020] The thickened portions of the sheet metal part may be
obtained by using flexibly rolled plates ("tailor rolled blanks")
in which the thickness progression and optionally the strength
progression is obtained by varying the roll gap.
[0021] The above aspects of this disclosure and other aspects are
described in greater detail below with reference to the attached
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is an exploded perspective view of a conventional
prior art structure of a rear floor part.
[0023] FIG. 2a is a perspective view of a sheet metal blank plate
with locally thickened portions applied by patch welding to produce
a rear floor part.
[0024] FIG. 2b is a perspective view of a fully formed rear floor
part formed from the sheet metal blank plate shown in FIG. 2a.
[0025] FIG. 3a is a perspective view of a sheet metal blank plate
with locally thickened portions applied by patch welding to produce
an alternative embodiment of a rear floor part
[0026] FIG. 3b is a perspective view of a fully formed alternative
embodiment of a rear floor part formed from the sheet metal blank
plate shown in FIG. 3a.
DETAILED DESCRIPTION
[0027] The illustrated embodiments are disclosed with reference to
the drawings. However, it is to be understood that the disclosed
embodiments are intended to be merely examples that may be embodied
in various and alternative forms. The figures are not necessarily
to scale and some features may be exaggerated or minimized to show
details of particular components. The specific structural and
functional details disclosed are not to be interpreted as limiting,
but as a representative basis for teaching one skilled in the art
how to practice the disclosed concepts.
[0028] Referring to FIG. 1, a conventional rear floor part assembly
for a motor vehicle is shown that is constructed according to a
prior art construction. The floor part assembly consists of a sheet
metal part 1 that is cut to size and is formed to the required
geometric shape to provide the required functional parts and
connecting regions. A supporting frame 2 is positioned below and
subsequently assembled to the sheet metal part.
[0029] Referring to FIG. 2a, a rear floor part of a vehicle is
shown to include a sheet metal part 3 having an outer contour that
is cut to size. The sheet metal part 3 is a thin-walled boron steel
having a thickness of 0.7 or 0.65 mm, or less. Local thickened
portions 4 are applied onto the planar sheet metal part 3. The
local thickened portions 4 are attached, for example, by patch
welding technology. The small planar sheet metal plates 4 in the
"soft" state before forming are welded, expediently by laser
welding or spot welding, or pressed onto the planar base plate made
of boron steel to form the thickened portions.
[0030] Referring to FIG. 2b, the sheet metal part 3 is shown in a
final shape obtained after further forming. The thickened portions
4 and the sheet metal part 3 are heated together in a furnace to
950.degree. C. and are then formed and hardened. The structural
properties of the component are accurately adjusted to the
respective structural requirements.
[0031] The structure obtained may be similar to the arrangement
shown in FIG. 1 that has longitudinal members and cross-members
that provide a conventional rear floor structure. The rear floor
structure formed by the sheet metal part 3 does not require the
separate supporting frame 2 of the prior art as shown in FIG. 1,
but obtains the required properties from the thickened portions 4
that are directly and integrally formed with the sheet metal part
3. The same approach would naturally also apply if the component
were used as a front floor part that is designed to absorb a
head-on collision and side impacts.
[0032] Referring to FIG. 3a, a rear floor part 5 is illustrated
that corresponds to the sheet metal part 3 of FIG. 2a. Thickened
portions 6 are applied to the planar sheet metal blank 5 and are
fastened by laser welding or spot welding to the sheet metal part
5. In this case, the sheet metal plate consists of boron steel but
alternatively may be formed of more easily formed FeMn steel, FeAl
steel or other high-grade steels.
[0033] Referring to FIG. 3b, the rear floor part 5 is shown after
being provided with the thickened portions 6, subjected to heat
treatment, geometrically formed and hardened. This structure is
self-supporting and does not require an additional supporting
frame. Longitudinal ribs 7 are incorporated in the structure that
provide good energy absorption properties in the event of a rear
collision. The rear floor plate provides an entirely novel energy
absorption mechanism that is substantially more efficient than
conventional structures that have separately formed and
subsequently assembled longitudinal members. In the event of a
crash, the loads are not introduced locally but in a planar manner
to achieve a more uniform load distribution.
[0034] The above-described novel structural solutions may be
integrated into the vehicle structure using conventional joining
techniques. No further cost in terms of production technology is
required.
[0035] The embodiments described above are specific examples that
do not describe all possible forms of the disclosure. The features
of the illustrated embodiments may be combined to form further
embodiments of the disclosed concepts. The words used in the
specification are words of description rather than limitation. The
scope of the following claims is broader than the specifically
disclosed embodiments and also includes modifications of the
illustrated embodiments.
* * * * *