High-strength metal sheet for vehicles

Abstract

This invention provides a high-strength metal sheet for vehicles. The sheet includes elliptical protrusions extending from it. The protrusions include a first protrusion and a second protrusion, the longer axis of the first protrusion pointing in a first direction, and the longer axis of the second protrusion pointing in a second direction. A bridging portion is disposed on a portion of a flat sheet located between the protrusions; a flat portion is disposed on the flat sheet and surrounded by the first protrusion, the second protrusion, and the bridging portion, thereby separating the flat portions from each other.

Description

Technical Field

[0001] This application relates essentially to high-strength metal sheet for vehicles, and more specifically, to a high-strength metal sheet for vehicles that, through its structure, increases the strength of the sheet and reduces its thickness, thereby reducing the weight of the sheet and improving the fuel efficiency of the vehicle using the sheet. Background Technology

[0002] In vehicles, sheet metal is commonly used for various components, such as muffler housings and heat insulators in exhaust systems, as well as chassis panels. Typically, commonly used vehicle sheet metal features a circular embossed pattern. Among existing sheet metal with circular embossed patterns, such as... Figure 10 As shown, the flat, unprotruding portions are continuously connected, thereby reducing its resonant frequency and intensity.

[0003] Furthermore, reducing the thickness of vehicle panels for lightweight structures may decrease the strength of the panels, thereby reducing their durability and vibration performance. Therefore, vehicles using existing vehicle panels currently in use struggle to reduce weight and improve fuel efficiency.

[0004] The above statements are intended only to help understand the background art of this application, and are not intended to imply that this application falls within the scope of prior art known to those skilled in the art. Summary of the Invention

[0005] Accordingly, this application provides a high-strength metal sheet for vehicles, which, through its structure, can increase the strength of the sheet and reduce its thickness, thereby reducing the weight of the sheet and improving the fuel efficiency of vehicles using the sheet.

[0006] According to one aspect of this application, a high-strength metal sheet for a vehicle is provided. The sheet may be a flat sheet and may include a plurality of raised sections and bridging portions. The plurality of elliptical raised sections protrude from the sheet, wherein the plurality of elliptical raised sections include first raised sections and second raised sections, the longer axis of each first raised section pointing towards a first direction, and the longer axis of each second raised section pointing towards a second direction; the bridging portions are disposed on a portion of the flat sheet located between the first raised sections and the second raised sections; and the flat portion disposed on the flat sheet is surrounded by the first raised sections, the second raised sections, and the bridging portions, thereby spacing the flat portions apart from each other. Specifically, the first direction may intersect the second direction at a predetermined angle.

[0007] According to an exemplary embodiment of this application, the height of each first protrusion can vary continuously along the longer axis. Furthermore, the height of each first protrusion can vary continuously along the shorter axis. Specifically, each first protrusion may include: a first central portion that is convex and has a first curvature; a first peripheral portion that is concave and has a second curvature greater than the first curvature; and a first side portion disposed between the first central portion and the first peripheral portion that is convex and has a third curvature greater than the first curvature.

[0008] Furthermore, according to an exemplary embodiment of this application, the height of each second protrusion can continuously vary along the longer axis. The height of each second protrusion can also continuously vary along the shorter axis. Specifically, each second protrusion may include: a second central portion that is convex and has a fourth curvature; a second peripheral portion that is concave and has a fifth curvature, the fifth curvature being greater than the fourth curvature; and a second side portion disposed between the second central portion and the second peripheral portion that is convex and has a sixth curvature, the sixth curvature being greater than the fourth curvature.

[0009] According to an exemplary embodiment of this application, each bridging portion can be integrally connected to a first side portion of a corresponding first raised portion and a second side portion of a corresponding second raised portion. The height of the bridging portion can be less than the maximum height of the raised portion with the smaller height among the first and second raised portions. Specifically, the height of the bridging portion can be approximately 0.5 to 0.8 times the maximum height of the raised portion with the smaller height among the first and second raised portions. Furthermore, each bridging portion can be located at the position where the distance between the corresponding first raised portion and the corresponding second raised portion is shortest. The first and second raised portions can be formed by a process of printing elliptical raised portions on the flat plate.

[0010] In the high-strength metal sheet for vehicles according to an exemplary embodiment of this application, the flat portions of the flat sheet are separated from each other by protrusions and bridging portions, rather than being continuously connected. Therefore, compared to the flat portions of existing sheets, the strength and resonant frequency of the sheet can be significantly improved. Accordingly, due to the improved strength, the thickness of the sheet can be reduced while maintaining the sheet's performance at the same level as existing sheets. Furthermore, reducing the thickness reduces the weight and material usage of the sheet. Attached Figure Description

[0011] The above and other objects, features, and other advantages of this application will become clearer from the detailed description presented below in conjunction with the accompanying drawings, in which:

[0012] Figure 1A plan view of a high-strength metal sheet according to an exemplary embodiment of this application;

[0013] Figure 2 For the exemplary embodiments of this application along Figure 1 The cross-sectional view obtained by line AA;

[0014] Figure 3 For the exemplary embodiments of this application along Figure 1 The cross-sectional view obtained by line BB;

[0015] Figure 4A For exemplary embodiments according to this application Figure 1 A magnified view of a portion of the document;

[0016] Figure 4B For exemplary embodiments according to this application Figure 1 A magnified view of a portion of the document;

[0017] Figure 5 For the exemplary embodiments of this application along Figure 4B The cross-sectional view obtained by the line CC;

[0018] Figure 6 For the exemplary embodiments of this application along Figure 4B The cross-sectional view obtained by the line DD;

[0019] Figure 7 A plan view of a high-strength metal sheet according to another exemplary embodiment of this application;

[0020] Figure 8 For another exemplary embodiment of this application along Figure 7 The cross-sectional view obtained by the line EE;

[0021] Figure 9 For another exemplary embodiment of this application along Figure 7 The cross-sectional view obtained by the line FF;

[0022] Figure 10 This is a plan view showing a panel for a vehicle based on the relevant technology. Detailed Implementation

[0023] It should be understood that the term “vehicle” or “of a vehicle” or other similar terms as used herein generally include motor vehicles, such as passenger cars including sport utility vehicles (SUVs), buses, trucks, various commercial vehicles, boats including various vessels, aircraft, etc., and includes hybrid vehicles, electric vehicles, combustion vehicles, plug-in hybrid electric vehicles, hydrogen-powered vehicles, and other alternative fuel vehicles (e.g., fuels derived from non-fossil energy sources).

[0024] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit this application. As used herein, the singular forms “a,” “an,” and “described” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that when the terms “comprising” and / or “including” are used in this specification, they indicate the presence of the stated feature, integral, step, operation, element, and / or component, but do not exclude the presence or inclusion of one or more other features, integrals, steps, operations, elements, components, and / or groups thereof. As described herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0025] Unless otherwise stated or obvious from the context, the term "approximately" is understood to mean within the normal tolerance range in this field, such as within an average of 2 standard deviations. "Approximately" can be understood as within 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, 0.1%, 0.05%, or 0.01% of the specified value. All numerical values ​​provided herein are modified by the term "approximately" unless the context clearly indicates otherwise.

[0026] Exemplary embodiments of this application will now be described with reference to the accompanying drawings.

[0027] In the attached diagram, Figures 1 to 6 A high-strength metal sheet according to an exemplary embodiment of this application is shown. For example... Figures 1 to 6 As shown, the high-strength plate according to this application can be a flat plate 100 having a plurality of elliptical protrusions 110 and 120 protruding therefrom.

[0028] A flat plate 100 can be manufactured by transforming a metallic material (such as steel sheet or aluminum material) into a flat shape with a predetermined thickness. A plurality of elliptical protrusions 110 and 120 can be arranged on the flat plate 100 in both horizontal and vertical directions, and can be classified as first protrusions 110 and second protrusions 120 based on the orientation of their longer axes. Among the plurality of elliptical protrusions 110 and 120, the protrusion with its longer axis oriented in a first direction is the first protrusion 110, and the protrusion with its longer axis oriented in a second direction is the second protrusion 120.

[0029] The first and second directions can be configured to intersect each other at a predetermined angle. For example, the first direction can be configured to intersect the second direction at an angle of approximately 60° to 120°. Figure 1 As shown, the first direction can be configured to intersect the second direction at approximately 90°. In other words, the longer axis of the first protrusion 110 can be inclined at a predetermined angle relative to the longer axis of the second protrusion 120. Similarly, the longer axis of the second protrusion 120 can be inclined at a predetermined angle relative to the longer axis of the first protrusion 110. The first protrusions 110 disposed on the flat plate 100 can be spaced apart from each other at a predetermined distance. Furthermore, the second protrusions 120 disposed on the flat plate 100 can be spaced apart from each other at a predetermined distance.

[0030] like Figure 2 and Figure 3 As shown, the height of each first protrusion 110 can continuously vary along its longer axis (i.e., the direction of the longer axis). Furthermore, the height of each first protrusion 110 can continuously vary along its shorter axis (i.e., the direction of the shorter axis). Since the height of each first protrusion 110 can continuously vary along its longer axis, the height of each first protrusion 110 can vary based on its position along the longer axis. Furthermore, since the height of each first protrusion 110 can continuously vary along its shorter axis, the height of each first protrusion 110 can vary based on its position along the shorter axis.

[0031] like Figure 2 As shown, the first raised section 110 can have different height values ​​at points labeled P1, P2, P3, and P4. Furthermore, as... Figure 3 As shown, the first protrusion 110 can have different height values ​​at points labeled P5, P6, P7, and P8. The curvature of the first protrusion 110 in both the longer and shorter axial directions, as described above, can be between D20 and 200. Furthermore, the length of the longer axis of the first protrusion 110 can be between 20 mm and 200 mm.

[0032] like Figure 4A As shown, the first raised portion 110 may include a first central portion 111, a first peripheral portion 112, and a first side portion 113. The first central portion 111 may be disposed on the uppermost side portion of the first raised portion 110. The first central portion 111 may be convex and have a first curvature in the direction of the longer axis. Furthermore, the first central portion 111 may be convex and also have a first curvature in the direction of the shorter axis.

[0033] The first peripheral portion 112 can be disposed on the lowermost portion of the first protrusion 110. The first peripheral portion 112 can be concave and have a second curvature in the direction of the longer axis. The value of the second curvature can be set to be greater than the value of the first curvature. Furthermore, the first peripheral portion 112 can be concave and also have a second curvature in the direction of the shorter axis. The first side portion 113 can be integrally formed with the first central portion 111 and the first peripheral portion 112, and disposed between the first central portion 111 and the first peripheral portion 112. The first side portion 113 can be convex and have a third curvature in the direction of the longer axis. The value of the third curvature can be set to be greater than the value of the first curvature. The first side portion 113 can be convex and have a third curvature in the direction of the shorter axis. The first protrusion 110 constructed as described above can have three different curvatures in the direction of the longer axis and three different curvatures in the direction of the shorter axis. In other words, the first protrusion 110 can have different curvatures depending on the predetermined regions in the directions of the longer axis and the shorter axis.

[0034] refer to Figure 2 The first protrusion 110 can have its maximum height at point P4, which is located at the center of the first central portion 111. Figure 3 Point P8 shown in the image can be located at the same position as point P4. Furthermore, the height of the second raised section 120 can vary continuously along the longer axis. The height of the second raised section 120 can also vary continuously along the shorter axis.

[0035] Since the height of each second protrusion 120 can vary continuously along the longer axis, the height of the second protrusion 120 can vary based on its position along the longer axis. Furthermore, since the height of the second protrusion 120 can vary continuously along the shorter axis, the height of the second protrusion 120 can vary based on its position along the shorter axis.

[0036] like Figure 3 As shown, the second convex feature 120 can have different height values ​​at points labeled P9, P10, P11, and P12. Figure 2 As shown, the second protrusion 120 may have different height values ​​at points labeled P13, P14, P15, and P16. The curvature of the second protrusion 120 in both the longer and shorter axial directions, as described above, may be between D20 and 200. Furthermore, the length of the longer axis of the second protrusion 120 may be between 20 mm and 200 mm.

[0037] like Figure 4BAs shown, the second protrusion 120 may include a second central portion 121, a second peripheral portion 122, and a second side portion 123. The second central portion 121 may be disposed on the uppermost side portion of the second protrusion 120. The second central portion 121 may be convex and have a fourth curvature in the direction of the longer axis. Furthermore, the second central portion 121 may be convex and also have a fourth curvature in the direction of the shorter axis. The curvature of the second central portion 121 may be the same as the curvature (i.e., the first curvature) of the first central portion 111. In other words, the fourth curvature may be the same as the first curvature.

[0038] Furthermore, the second circumferential portion 122 can be disposed on the lowest portion of the second protrusion 120. The second circumferential portion 122 can be concave and have a fifth curvature in the direction of the longer axis. The value of the fifth curvature can be set to be greater than the value of the fourth curvature. The second circumferential portion 122 can also be concave and have a fifth curvature in the direction of the shorter axis. Furthermore, the curvature of the second circumferential portion 122 can be the same as the curvature of the first circumferential portion 112 (i.e., the second curvature). In other words, the fifth curvature can be the same as the second curvature.

[0039] The second side portion 123 can be integrally formed with the second central portion 121 and the second peripheral portion 122, and is arranged between the second central portion 121 and the second peripheral portion 122. Furthermore, the second side portion 123 can be convex and has a sixth curvature in the direction of the longer axis. The value of the sixth curvature can be set to be greater than the value of the fourth curvature. The second side portion 123 can also be convex and have a sixth curvature in the direction of the shorter axis.

[0040] Furthermore, the curvature of the second side portion 123 can be the same as the curvature of the first side portion 113 (i.e., the third curvature). In other words, the sixth curvature can be the same as the third curvature. As described above, the second protrusion 120 can have three different curvatures in the longer axis direction and three different curvatures in the shorter axis direction. In other words, the second protrusion 120 can have different curvatures depending on the predetermined regions in the longer axis direction and the shorter axis direction.

[0041] refer to Figure 3 The second convex protrusion 120 can have its maximum height at point P12, which is located at the center of the second central portion 121. Figure 2 Point P16 shown in the diagram can be located at the same position as point P12. Additionally, refer to... Figures 1 to 6 The flat plate 100 may include bridging portions 130, each bridging portion 130 connecting a first protrusion 110 and a corresponding second protrusion 120. Each bridging portion 130 may be convex and have a predetermined curvature.

[0042] Specifically, the bridging portion 130 can be integrally connected to the first side portion 113 of the first protrusion 110 and the second side portion 123 of the second protrusion 120, and the height h can be less than the maximum height H of the first protrusion 110 (see...). Figure 2 ).like Figures 7 to 9 As shown, when the first protrusion 110 and the second protrusion 120' have different maximum heights H1 and H2, the height h1 of the bridging portion 130 can be less than the smaller of the maximum heights. The maximum height of the first protrusion 110 can be determined to be the same as or different from the maximum height of the second protrusion 120 or 120'. For example, the maximum height of the first protrusion 110 can be greater than or less than the maximum height of the second protrusion 120 or 120'.

[0043] In the region forming the bridging portion 130, neither the first peripheral portion 112 nor the second peripheral portion 122 is provided. Since each bridging portion 130 can be arranged between the first protrusion 110 and the second protrusion 120, the flat plate 100 can be provided with a flat area (i.e., a flat portion) surrounded by the first protrusion 110, the second protrusion 120, and the bridging portion 130. Each flat portion 140 formed on the flat plate 100 is a region where no elliptical protrusions 110 and 120 or bridging portions 130 are formed. Figure 1 and Figure 7 As shown, the flat portions 140 can be separated from each other by the first protrusion 110, the second protrusion 120 and the bridging portion 130. In other words, the flat portions 140 can be separated by the first protrusion 110, the second protrusion 120 and the bridging portion 130, so that each flat portion 140 may not be connected to the other flat portions 140 (e.g., they may be spaced apart from each other).

[0044] Because the flat portions 140 (i.e., the flat areas arranged between the elliptical protrusions 110 and 120) can be separated from each other without being continuously connected, the high-strength sheet metal according to this application can have the effect that its strength and resonant frequency are significantly improved compared to existing sheet metal. As described above, the height of the bridging portion 130 can be determined to be less than the maximum height of the protrusion with the smaller height among the first protrusion 110 and the second protrusion 120 or 120' (hereinafter referred to as the lower protrusion).

[0045] Specifically, the height of the bridging portion 130 can be less than approximately 50% to 80% of the maximum height of the lower relief. In other words, the height of the bridging portion 130 can be equal to or less than approximately 0.5 to 0.8 times the maximum height of the lower relief. The height of the bridging portion 130 can be approximately 0.5 to 0.8 times the maximum height of the lower relief. The height of the bridging portion 130 can be limited by the maximum height of the lower relief, thereby improving the formability, durability, and vibration performance of the high-strength sheet metal. Furthermore, when the bridging portion 130 is formed between the first relief 110 and the second relief 120, the bridging portion 130 can be formed at the position where the distance between the first relief 110 and the second relief 120 is shortest.

[0046] Specifically, the heights of the first raised portion 110 and the second raised portions 120 and 120' can be determined based on the flat portion 140. Furthermore, the first raised portion 110 and the second raised portion 120 can be formed by a process of printing elliptical raised portions on the flat plate 100. For example, the first raised portion 110 and the second raised portion 120 can be formed by a drawing process or an embossing process. Specifically, the first raised portion 110 and the second raised portion 120 can be formed on the flat plate 100 to protrude in the same direction as a convex shape.

[0047] Since the first raised surface 110 and the second raised surface 120 can be formed by printing raised surfaces, the first raised surface 110 and the second raised surface 120 can be formed by tucking (or stretching) a predetermined area of ​​the flat plate 100. Therefore, during the forming process, the thickness of the first raised surface 110 and the second raised surface 120 can be reduced to be thinner than the thickness of the flat plate 100, respectively. Accordingly, when setting the thickness of the first raised surface 110 and the second raised surface 120 during the forming process, it is conceivable that the respective thicknesses of the elliptical raised surfaces 110 and 120 become thinner than the thickness of the flat plate 100. During the forming of the elliptical raised surfaces 110 and 120, the thickness gradually decreases in the central portions 111 and 121 and the side portions 113 and 123.

[0048] Specifically, each of the first relief 110 and the second relief 120 can be formed to have a thickness of approximately 70% or more of the thickness of the flat plate 100. Furthermore, when machining the elliptical reliefs 110 and 120 on the flat plate 100, the maximum height of each elliptical relief 110 and 120 can be set such that the thickness reduction rate of the flat plate 100, which serves as the substrate, is approximately 30% or less.

[0049] The high-strength sheet metal according to this application can have the following effects: compared with existing sheet metal, its strength and resonant frequency can be significantly improved. This is because, in the high-strength sheet metal according to this application, the flat portions 140 of the flat sheet metal 100 are separated from each other by elliptical protrusions 110 and 120 and bridging portions 130, rather than being continuously connected. In prior art sheet metal, flat areas without protrusion structures are continuously connected (see...). Figure 10 This causes vibration and reduces strength.

[0050] Due to the improved strength of the high-strength sheet metal according to this application, the thickness of the sheet metal can be reduced while maintaining its performance. The reduced thickness also reduces the weight and material usage of the sheet metal. The high-strength sheet metal can be used in vehicle body panels, muffler housings, heat insulation components, etc., to reduce vehicle weight and improve fuel efficiency. For example, high-strength sheet metal can be used in entire sections of a vehicle body panel or in sections with lower strength levels, thereby improving the strength and vibration characteristics of the vehicle body. For instance, a high-strength sheet metal used in a muffler housing can reduce the weight of the muffler housing while maintaining the muffler's strength at the same level as existing muffler housings.

[0051] Although exemplary embodiments of this application have been described for illustrative purposes, those skilled in the art will understand that various modifications, additions, and deletions may be made without departing from the scope and spirit of this application as disclosed in the appended claims.

Claims

1. A high-strength sheet metal member for a vehicle, the sheet member being a flat sheet member, the sheet member comprising: a plurality of elliptical embossments protruding from the sheet member, wherein the plurality of elliptical embossments includes first embossments and second embossments, a longer axis of each first embossment faces a first direction, a longer axis of each second embossment faces a second direction; a plurality of bridges provided on a portion of the flat sheet member between the first embossments and the second embossments to connect the first embossments and the second embossments, wherein a height of the bridges is less than a maximum height of the first embossments and the second embossments; and a plurality of flat portions provided on the flat sheet member and surrounded by the first embossments, the second embossments, and the bridges, such that the flat portions are spaced apart from each other.

2. The high-strength sheet metal part for a vehicle according to claim 1, wherein The first direction intersects the second direction at a predetermined angle.

3. The high-strength sheet metal part for a vehicle according to claim 1, wherein A height of each first embossment continuously varies in a direction of the longer axis.

4. The high-strength sheet metal part for a vehicle according to claim 3, wherein A height of each first embossment continuously varies in a direction of the shorter axis.

5. The high-strength sheet metal part for a vehicle according to claim 4, wherein Each first embossment includes: a first central portion that is convex and has a first curvature; a first peripheral portion that is concave and has a second curvature, the second curvature being greater than the first curvature; a first side portion provided between the first central portion and the first peripheral portion, the first side portion being convex and having a third curvature, the third curvature being greater than the first curvature.

6. The high-strength sheet metal part for a vehicle according to claim 4, wherein A height of each second embossment continuously varies in a direction of the longer axis.

7. The high-strength sheet metal part for a vehicle according to claim 6, wherein A height of each second embossment continuously varies in a direction of the shorter axis.

8. The high-strength sheet metal part for a vehicle according to claim 7, wherein Each second embossment includes: a second central portion that is convex and has a fourth curvature; a second peripheral portion that is concave and has a fifth curvature, the fifth curvature being greater than the fourth curvature; a second side portion provided between the second central portion and the second peripheral portion, the second side portion being convex and having a sixth curvature, the sixth curvature being greater than the fourth curvature.

9. The high-strength sheet metal part for a vehicle of claim 8, wherein, Each of the plurality of bridges is integrally connected to a first side portion of a respective one of the first embossments and a second side portion of a respective one of the second embossments, a height of the bridge being less than a maximum height of the embossment having the smaller height among the first embossments and the second embossments.

10. The high-strength sheet metal part for a vehicle of claim 9, wherein, The height of the bridge is about 0.5 to 0.8 times the maximum height of the embossment having the smaller height among the first embossments and the second embossments.

11. The high-strength sheet metal part for a vehicle of claim 9, wherein, Each bridge is provided at a position where a distance between the respective first embossment and the respective second embossment is the shortest.

12. The high strength sheet metal part for a vehicle of claim 9, wherein, The first embossments and the second embossments protrude convexly in a single direction.

13. The high strength sheet metal part for a vehicle of claim 1, wherein, The first embossments and the second embossments are formed by a process of printing elliptical embossments on the flat sheet member.

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