Method of manufacturing a vehicle body structure component to include a reinforcement region

Abstract

A method of manufacturing a vehicle body structure component is described. The method includes extruding a tube to include at least one reinforced region extending along a length of the tube. The tube has a first thickness in the at least one reinforced region and a second thickness in other regions of the tube. The first thickness is greater than the second thickness. The method further includes cutting a blank from the tube such that the blank includes at least a portion of the at least one reinforced region, and forming the blank into a desired shape of the component.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to methods of manufacturing a vehicle body structural component to include a reinforcement region. BACKGROUND

[0002] The information provided in this section is for the purpose of generally presenting the context of the disclosure. The work of the inventors currently named in this section relates to the development of the presently claimed disclosure, to the extent that it is described in this section and, at the time of filing, is not considered to be prior art to the disclosure. The disclosure was invented by the inventors named below as part of their work at the University of Waterloo.

[0003] Extrusion is a process in which material is pushed through a die to produce an extruded product having a desired cross-section. The material is often a metal, such as aluminum or steel. Extruded products are used in various industries to produce components such as railway rails, vehicle frames, tracks, and pipe fittings. SUMMARY

[0004] The present disclosure describes a method of manufacturing a vehicle body structural component. In one example, the method includes extruding a tube to include at least one reinforcement region extending along a length of the tube. The tube has a first thickness in the at least one reinforcement region and a second thickness in other regions of the tube. The first thickness is greater than the second thickness. The method further includes cutting a blank from the tube such that the blank includes at least a portion of the at least one reinforcement region, and forming the blank into a desired shape of the component.

[0005] In one aspect, the tube is a rectangular tube having four sides, and the method further includes extruding the tube to include the at least one reinforcement region on each side of the tube.

[0006] In one aspect, the at least one reinforcement region includes a pair of reinforcement regions that protrude from an outer surface of the tube.

[0007] In one aspect, the at least one reinforcement region includes a pair of reinforcement regions that protrude from an inner surface of the tube.

[0008] In one aspect, the at least one reinforcement region includes a pair of first reinforcement regions that protrude from an outer surface of the tube and a pair of second reinforcement regions that protrude from an inner surface of the tube.

[0009] In one aspect, the first reinforcement regions are spaced apart from each other by a first distance, and the second reinforcement regions are spaced apart from each other by a second distance that is less than the first distance.

[0010] In one aspect, the component includes a first flat section, a second flat section oriented at a non-zero angle relative to the first flat section, and a curved section connecting the first flat section and the second flat section to each other, and the method further includes positioning the at least one reinforced region on the tube such that the at least one reinforced region resides in the curved section when the blank is formed into the desired shape of the component.

[0011] In one aspect, the first flat section, the second flat section, and the curved section extend along a length of the component.

[0012] In one aspect, the tube is a cylindrical tube, and the method further includes twisting the tube prior to cutting the blank from the tube such that the at least one reinforced region is misaligned with a length of the blank.

[0013] In one aspect, the tube is a rectangular tube, and the method further includes bending the tube prior to cutting the blank from the tube such that the at least one reinforced region is non-linear.

[0014] In one aspect, the method further includes cutting the blank from the tube such that the at least one reinforced region is misaligned with a length of the blank.

[0015] In another example of the method of manufacturing a vehicle body structural component described in the disclosure, the method includes extruding a rectangular tube to include at least one pair of reinforced regions on each side of the tube. The at least one pair of reinforced regions extends along a length of the tube. The tube has a first thickness in the reinforced regions and a second thickness in other regions of the tube. The first thickness is greater than the second thickness. The method further includes cutting a blank from the tube on each side of the tube such that the blank includes at least a portion of the at least one pair of reinforced regions, and forming the blank into a desired shape of the component having a u-shaped cross-section with a flange protruding from an end of the u-shaped cross-section.

[0016] In one aspect, the component includes a first flat section, a second flat section, a third flat section, a first curved section connecting the first flat section and the second flat section to each other, and a second curved section connecting the second flat section and the third flat section to each other. The first flat section, the second flat section, and the third flat section, and the first curved section and the second curved section form a u-shaped cross-section.

[0017] In one aspect, the method further includes positioning the at least one pair of reinforced regions on the tube such that the at least one pair of reinforced regions resides in the first curved section and the second curved section of the component when the blank is formed into the desired shape of the component.

[0018] In one aspect, the component further includes: a third curved section connecting one of the flanges to the first flat section; and a fourth curved section connecting another of the flanges to the third flat section.

[0019] In one aspect, the method further includes positioning the at least one pair of reinforcement regions on the tube such that, when the blank is formed into the desired shape of the component, the at least one pair of reinforcement regions resides in the third curved section and the fourth curved section of the component.

[0020] In one aspect, the at least one pair of reinforcement regions includes a first pair of reinforcement regions protruding from an outer surface of the tube and a second pair of reinforcement regions protruding from an inner surface of the tube, and the method further includes positioning the first pair of reinforcement regions and the second pair of reinforcement regions on the tube such that, when the blank is formed into the desired shape of the component, the first pair of reinforcement regions resides in the first curved section and the second curved section of the component and the second pair of reinforcement regions resides in the third curved section and the fourth curved section of the component.

[0021] In one aspect, the second thickness of the tube on one side of the tube is different than the second thickness of the tube on another side of the tube.

[0022] In one aspect, the method further includes placing the at least one pair of reinforcement regions on one side of the tube in one manner and placing the at least one pair of reinforcement regions on another side of the tube in a different manner.

[0023] In one aspect, the method further includes extruding the tube such that the tube has a width and a height that is different than the width.

[0024] The present invention provides the following technical solutions:

[0025] 1. A method of manufacturing a vehicle body structural component, the method comprising:

[0026] extruding a tube to include at least one reinforcement region extending along a length of the tube, the tube having a first thickness in the at least one reinforcement region and a second thickness in other regions of the tube, wherein the first thickness is greater than the second thickness;

[0027] cutting a blank from the tube such that the blank includes at least a portion of the at least one reinforcement region; and

[0028] forming the blank into a desired shape of the component.

[0029] 2. The method of solution 1, wherein the tube is a rectangular tube having four sides, the method further comprising extruding the tube to include the at least one reinforcement region on each side of the tube.

[0030] 3. The method of aspect 2, wherein the at least one reinforcement region comprises a pair of reinforcement regions that protrude from an outer surface of the tube.

[0031] 4. The method of aspect 2, wherein the at least one reinforcement region comprises a pair of reinforcement regions that protrude from an inner surface of the tube.

[0032] 5. The method of aspect 2, wherein the at least one reinforcement region comprises a pair of first reinforcement regions that protrude from an outer surface of the tube and a pair of second reinforcement regions that protrude from an inner surface of the tube.

[0033] 6. The method of aspect 5, wherein the first reinforcement regions are spaced apart from each other by a first distance and the second reinforcement regions are spaced apart from each other by a second distance, the second distance being less than the first distance.

[0034] 7. The method of aspect 1, wherein the component comprises a first flat section, a second flat section oriented at a non-zero angle relative to the first flat section, and a curved section connecting the first and second flat sections to each other, the method further comprising positioning the at least one reinforcement region on the tube such that, when the blank is formed into the desired shape of the component, at least one reinforcement region resides in the curved section.

[0035] 8. The method of aspect 7, wherein the first flat section, the second flat section, and the curved section extend along a length of the component.

[0036] 9. The method of aspect 1, wherein the tube is a cylindrical tube, the method further comprising twisting the tube prior to cutting the blank from the tube such that the at least one reinforcement region is not aligned with a length of the blank.

[0037] 10. The method of aspect 1, wherein the tube is a rectangular tube, the method further comprising bending the tube prior to cutting the blank from the tube such that the at least one reinforcement region is non-linear.

[0038] 11. The method of aspect 1, further comprising cutting the blank from the tube such that the at least one reinforcement region is not aligned with a length of the blank.

[0039] 12. A method of manufacturing a vehicle body structure component, the method comprising:

[0040] extruding a rectangular tube to include at least one pair of reinforcement regions on each side of the tube, the at least one pair of reinforcement regions extending along a length of the tube, the tube having a first thickness in the reinforcement regions and a second thickness in other regions of the tube, wherein the first thickness is greater than the second thickness;

[0041] cutting a blank from the tube from each side of the tube such that the blank includes at least a portion of the at least one pair of reinforcement regions; and

[0042] forming the blank into a desired shape of the component having a u-shaped cross-section with flanges protruding from ends of the u-shaped cross-section.

[0043] 13. The method of aspect 12, wherein the component includes a first flat section, a second flat section, a third flat section, a first curved section connecting the first flat section and the second flat section to each other, and a second curved section connecting the second flat section and the third flat section to each other, the first flat section, the second flat section, and the third flat section, and the first curved section and the second curved section forming the u-shaped cross-section.

[0044] 14. The method of aspect 13, further comprising positioning the at least one pair of reinforcement regions on the tube such that, when the blank is formed into the desired shape of the component, the at least one pair of reinforcement regions reside in the first curved section and the second curved section of the component.

[0045] 15. The method of aspect 13, wherein the component further includes a third curved section connecting one of the flanges to the first flat section, and a fourth curved section connecting the other of the flanges to the third flat section.

[0046] 16. The method of aspect 15, further comprising positioning the at least one pair of reinforcement regions on the tube such that, when the blank is formed into the desired shape of the component, the at least one pair of reinforcement regions reside in the third curved section and the fourth curved section of the component.

[0047] 17. The method of Scheme 15, wherein the at least one pair of reinforcement regions comprises a first pair of reinforcement regions that protrude from an outer surface of the tube and a second pair of reinforcement regions that protrude from an inner surface of the tube, the method further comprising positioning the first pair of reinforcement regions and the second pair of reinforcement regions on the tube such that, when the blank is formed into the desired shape of the component, the first pair of reinforcement regions reside in the first curved section and the second curved section of the component and the second pair of reinforcement regions reside in the third curved section and the fourth curved section of the component.

[0048] 18. The method of Scheme 12, wherein the second thickness of the tube on one side thereof is different than the second thickness of the tube on another side thereof.

[0049] 19. The method of Scheme 12, further comprising placing the at least one pair of reinforcement regions on one side of the tube in one manner and placing the at least one pair of reinforcement regions on another side of the tube in a different manner.

[0050] 20. The method of Scheme 12, further comprising extruding the tube such that the tube has a width and a height that is different than the width.

[0051] Further areas of applicability of this disclosure will become apparent from the detailed description, the claims and the drawings. The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF DRAWINGS

[0052] The present disclosure will become more fully understood from the detailed description and the accompanying drawings, wherein:

[0053] Figure 1 is a perspective view of a first example of an extruded tube in accordance with the principles of the present disclosure;

[0054] Figure 2A is a perspective view of an end of the extruded tube of Figure 1 ;

[0055] Figure 2B is a perspective view of a portion of the extruded tube of Figure 1 ; Figure 2A within the circle 2B shown in ;

[0056] Figure 3A is a perspective view of the extruded tube of Figure 1 ;

[0057] Figure 3B is a perspective view of the extruded tube of Figure 3Aa cross-sectional perspective view of the blank and the door beam shown in

[0058] Figure 4 is a perspective view of an end of the extruded tube of

[0059] Figure 5A is a perspective view of a portion of the extruded tube of Figure 4 within a circle 5B shown in

[0060] Figure 5B is a perspective view of a portion of the extruded tube of Figure 4 within a circle 8B shown in Figure 5A

[0061] Figure 6A is a perspective view of the extruded tube of Figure 4 wherein several blanks are cut from the side of the extruded tube and one blank is formed into a door beam;

[0062] Figure 6B is a cross-sectional perspective view of the blank and the door beam shown in Figure 6A

[0063] Figure 7 is a perspective view of a third example of an extruded tube according to the principles of the present disclosure;

[0064] Figure 8A is a perspective view of an end of the extruded tube of Figure 7

[0065] Figure 8B is a perspective view of a portion of the extruded tube of Figure 7 within a circle 8C shown in Figure 8A

[0066] Figure 8C is a perspective view of a portion of the extruded tube of Figure 7 within a circle 8C shown in Figure 8A

[0067] Figure 9A is a perspective view of the extruded tube of Figure 7 wherein several blanks are cut from the side of the extruded tube and one blank is formed into a door beam;

[0068] Figure 9B is a cross-sectional perspective view of the blank and the door beam shown in Figure 9A

[0069] Figure 10A is a perspective view of a fourth example of an extruded tube according to the principles of the present disclosure;

[0070] Figure 10B is a perspective view of the extruded tube of Figure 10A ​​​​​​a perspective view of the extruded tube of

[0071] Figure 10C is Figure 10A a perspective view of the extruded tube of

[0072] Figure 11A is a perspective view of an extruded tube similar or identical to the extruded tube of Figure 1

[0073] Figure 11B is Figure 11A a perspective view of the extruded tube of

[0074] Figure 11C is Figure 11A a perspective view of the extruded tube of

[0075] Figure 12A is a perspective view of an extruded tube similar or identical to the extruded tube of Figure 1

[0076] Figure 12B is Figure 11A a perspective view of the extruded tube of

[0077] In the drawings, reference numerals can be repeated to identify similar and / or identical elements. DETAILED DESCRIPTION

[0078] Many vehicle body structure components are extruded. Examples of such components include door impact beams, cross car reinforcements, rocker sections, complete rockers, frame rails, bumper beams, and bumper beam reinforcements. Typically, extrusion produces a square or cylindrical tube having a constant thickness cross section, and several blanks are cut from the tube and formed (e.g., stamped, rolled) into the desired shape of the vehicle body structure component.

[0079] Sometimes, the cross section of a vehicle body structure component is hat-shaped, having straight sides and a bend connecting the straight sides to each other. During a vehicle impact, the high stress areas of the vehicle body structure component tend to be at the bend. To ensure that these areas can withstand the vehicle impact, the entire cross section of the extruded tube is thickened. As a result, other areas tend to be thicker than necessary, which increases the part cost and weight.

[0080] ​​A method of manufacturing a vehicle body structure component according to the present disclosure involves extruding a structure (e.g., a tube) to have a cross-sectional shape that has a reinforcement region that is thicker than other regions of the structure (e.g., the rest of the structure). Such a cross-sectional shape can be referred to as having a variable cross-sectional thickness. Additionally, the method involves positioning the reinforcement region on the structure so that, when the blank is cut from the structure and formed into the desired shape of the vehicle body structure component, the reinforcement region resides in a high stress region. In turn, the other regions of the structure can be thinner than the reinforcement region, which reduces part cost and weight while maintaining the structural integrity of the component.

[0081] In the following examples, the method of manufacturing a vehicle body structure component according to the present disclosure is described in the context of a hat-sectioned door beam. However, the techniques described herein can be used to manufacture other vehicle body structure components, such as a cross-car reinforcement, a rocker section, a complete rocker, a frame rail, a bumper beam, and a bumper beam reinforcement. Additionally, the techniques described herein can be used to manufacture extruded parts having other cross-sectional shapes and / or for use in other industries, such as the aircraft and construction industries, the marine, naval, or shipbuilding industries, and the heavy machinery and pressurized container manufacturing industries.

[0082] Referring now to Figure 1 , Figure 2A and Figure 2B , a rectangular tube 10 has four sides 12. Each side 12 of the tube 10 has an inner surface 14 and an outer surface 16. The tube 10 includes a pair of reinforcement regions 18 that protrude from the outer surface 16 of each side 12 and extend along a length 20 of the tube 10. The tube 10 has a thickness 22 in the reinforcement regions 18 and a thickness 24 in other regions of the tube 10 (e.g., the rest of the tube 10).

[0083] The thickness 22 of the tube 10 in the reinforcement regions 18 is greater than the thickness 24 of the tube 10 in the other regions. In one example, the thickness 22 of the tube 10 in the reinforcement regions 18 is equal to 3 millimeters (mm) and the thickness 24 of the tube 10 in the other regions is equal to 2.5 mm. Thus, in this example, the reinforcement regions 18 of the tube 10 are 0.5 mm thicker than the other regions of the tube 10. Each reinforcement region 18 has a width 25 (e.g., 6 mm). The thickness 22 of the tube 10 in the reinforcement regions 18, the thickness 24 of the tube 10 in the other regions, and / or the width 25 of one reinforcement region 18 on one side 12 of the tube 10 can be equal to or different from the thickness 22, the thickness 24, and / or the width 25 on another side 12 of the tube 10, respectively.

[0084] The two sides 12 of the tube 10 define a width 26 thereof, and the other two sides 12 of the tube 10 define a height 28 thereof. The width 26 of the tube 10 can be equal to or different than the height 28 of the tube 10. Thus, the dimensions of the sides 12 defining the width 26 of the tube 10 can be equal to or different than the dimensions of the sides 12 defining the height 28 of the tube 10. In one example, the width 26 of the tube 10 is 150 mm, and the height 28 of the tube 10 is 150 mm.

[0085] The longitudinal centerlines of the reinforcement regions 18 on each side 12 of the tube 10 are spaced apart by a distance 30. The distance 30 by which the longitudinal centerlines of the reinforcement regions 18 are spaced apart on one side 12 of the tube 10 can be equal to or different than the distance 30 by which the longitudinal centerlines of the reinforcement regions 18 are spaced apart on the other side 12 of the tube 10. In one example, the distance 30 by which the longitudinal centerlines of the reinforcement regions 18 are spaced apart is equal to 70 mm on each side 12 of the tube 10.

[0086] The tube 10 can be formed from metal using extrusion. The reinforcement regions 18 of the tube 10 can be formed integrally with the rest of the tube 10. For example, the reinforcement regions 18 of the tube 10 can be formed integrally with the rest of the tube 10 in a single extrusion operation.

[0087] Referring now to FIG. 2, Figure 3A and Figure 3B A blank 32 can be cut from each side 12 of the tube 10 such that the blank 32 includes at least a portion of each reinforcement region 18. In the illustrated example, each blank 32 includes a majority of the reinforcement regions 18 from one side 12 of the tube 10. Additionally, each blank 32 is cut such that the reinforcement regions 18 are aligned with the length 34 of the blank 32. Each blank 32 can be cut from one side 12 of the tube 10 using milling, electrical discharge machining, laser cutting, or water jet cutting. The rest of the tube 10 can be recycled.

[0088] Each blank 32 can be formed into a desired shape of a door beam 36 using room temperature stamping, hot stamping, or roll forming. The door beam 36 has a hat-shaped cross-section or a u-shaped cross-section with a flange 38 protruding from an end of the u-shaped cross-section. The door beam 36 includes a flat section 40, a flat section 42, a flat section 44, a curved section 46 connecting the flat sections 40, 42 to one another, and a curved section 48 connecting the flat sections 42, 44 to one another. The flat sections 40, 42, 44 and the curved sections 46, 48 form the u-shaped cross-section of the door beam 36. In various embodiments, a stiffening rib can be formed along a longitudinal centerline of the flat section 42, and the stiffening rib can be recessed relative to the rest of the flat section 42.

[0089] The vehicle door beam 36 further includes a curved section 50 connecting one of the flanges 38 to the flat section 40, and a curved section 52 connecting the other flange 38 to the flat section 44. As shown best in Figure 3B The reinforcement region 18 is positioned on the tube 10 such that, when the blank 32 is formed into the desired shape of the vehicle door beam 36, the reinforcement region 18 resides in the curved sections 50, 52 of the vehicle door beam 36. As a result, as shown best in Figure 2B The thickness 24 of the tube 10 in other regions can be less than the thickness 22 of the tube 10 in the reinforcement region 18 while maintaining the structural integrity of the vehicle door beam 36, as shown in

[0090] Each flat section 40, 44 of the vehicle door beam 36 is oriented at a non-zero angle 54 relative to the flat section 42 of the vehicle door beam 36. Each flange 38 of the vehicle door beam 36 is oriented at a non-zero angle 56 relative to the flat section 40 or 44. In the illustrated example, each non-zero angle 54, 56 is an obtuse angle. The flat sections 40, 42, 44 and the curved sections 46, 48, 50, 52 extend along a length 58 of the vehicle door beam 36. Each flat section and curved section described herein can be referred to as a straight side and a bend, respectively.

[0091] Referring now to Figure 4 , Figure 5A and Figure 5B The rectangular tube 60 has four sides 62. Each side 62 of the tube 60 has an inner surface 64 and an outer surface 66. The tube 60 includes a pair of reinforcement regions 68 that protrude from the outer surface 64 of each side 62 and extend along a length 70 of the tube 60. The tube 60 has a thickness 72 in the reinforcement regions 68 and a thickness 74 in other regions of the tube 60 (e.g., the remainder of the tube 60). The longitudinal edges of the reinforcement regions 68 can be tapered as shown, and the angle of each taper can be adjusted (e.g., different from the angle shown).

[0092] The thickness 72 of the tube 60 in the reinforcement regions 68 is greater than the thickness 74 of the tube 60 in other regions. In one example, the thickness 72 of the tube 60 in the reinforcement regions 68 is equal to 3 mm, and the thickness 74 of the tube 60 in other regions is equal to 2.5 mm. Thus, in this example, the reinforcement regions 68 of the tube 60 are 0.5 mm thicker than other regions of the tube 60. Each reinforcement region 68 has a width 75 (e.g., 6 mm). The thickness 72 of the tube 60 in the reinforcement regions 68, the thickness 74 of the tube 60 in other regions, and / or the width 75 of one reinforcement region 68 on one side 62 of the tube 60 can be equal to or different from the thickness 72, the thickness 74, and / or the width 75 on another side 62 of the tube 60, respectively.

[0093] The two sides 62 of the tube 60 define a width 76 thereof, and the other two sides 62 of the tube 60 define a height 78 thereof. The width 76 of the tube 60 can be equal to or different than the height 78 of the tube 60. Thus, the dimensions of the sides 62 defining the width 76 of the tube 60 can be equal to or different than the dimensions of the sides 62 defining the height 78 of the tube 60. In one example, the width 76 of the tube 60 is 150 mm, and the height 78 of the tube 60 is 150 mm.

[0094] The longitudinal centerlines of the reinforcement regions 68 on each side 62 of the tube 60 are spaced apart by a distance 80. The distance 80 by which the longitudinal centerlines of the reinforcement regions 68 are spaced apart on one side 62 of the tube 60 can be equal to or different than the distance 80 by which the longitudinal centerlines of the reinforcement regions 68 are spaced apart on the other side 62 of the tube 60. In one example, the distance 80 by which the longitudinal centerlines of the reinforcement regions 68 are spaced apart is equal to 38.5 mm on each side 62 of the tube 60.

[0095] The tube 60 can be formed from metal using extrusion. The reinforcement regions 68 of the tube 60 can be formed integrally with the rest of the tube 60. For example, the reinforcement regions 68 of the tube 60 can be formed integrally with the rest of the tube 60 in a single extrusion operation.

[0096] Referring now to FIG. 2, Figure 6A and Figure 6B a blank 82 can be cut from each side 62 of the tube 60 such that the blank 82 includes at least a portion of each reinforcement region 68. In the illustrated example, each blank 82 includes a majority of the reinforcement regions 68 from one side 62 of the tube 60. Additionally, each blank 82 is cut such that the reinforcement regions 68 are aligned with the length 84 of the blank 82. Each blank 82 can be cut from one side 62 of the tube 60 using milling, electrical discharge machining, laser cutting, or water jet cutting. The rest of the tube 60 can be recycled.

[0097] Each blank 82 can be formed into a desired shape of a vehicle door beam 86 using room temperature stamping, hot stamping, or roll forming. The vehicle door beam 86 has a hat-shaped cross-section or a u-shaped cross-section with a flange 88 protruding from an end of the u-shaped cross-section. The vehicle door beam 86 includes a flat section 90, a flat section 92, a flat section 94, a curved section 96 connecting the flat sections 90, 92 to one another, and a curved section 98 connecting the flat sections 92, 94 to one another. The flat sections 90, 92, 94 and the curved sections 96, 98 form the u-shaped cross-section of the vehicle door beam 86. In various embodiments, a stiffening rib can be formed along a longitudinal centerline of the flat section 92, and the stiffening rib can be recessed relative to the rest of the flat section 92.

[0098] The vehicle door impact beam 86 further includes a curved section 100 connecting one of the flanges 88 to the flat section 90, and a curved section 102 connecting the other flange 88 to the flat section 94. As shown best in Figure 6B The reinforcement regions 68 are positioned on the tube 60 such that, when the blank 82 is formed into the desired shape of the vehicle door impact beam 86, the reinforcement regions 68 reside in the curved sections 96, 98 of the vehicle door impact beam 86. As a result, as shown best in Figure 5A and Figure 5B The thickness 74 of the tube 60 in other regions can be less than the thickness 72 of the tube 60 in the reinforcement regions 68, while maintaining the structural integrity of the vehicle door impact beam 86, as shown in

[0099] Each flat section 90, 94 of the vehicle door impact beam 86 is oriented at a non-zero angle 104 relative to the flat section 92 of the vehicle door impact beam 86. Each flange 88 of the vehicle door impact beam 86 is oriented at a non-zero angle 106 relative to the flat section 90 or 94. In the illustrated example, each non-zero angle 104, 106 is an obtuse angle. The flat sections 90, 92, 94 and the curved sections 96, 98, 100, 102 extend along a length 108 of the vehicle door impact beam 86.

[0100] Referring now to Figure 7 , Figure 8A , Figure 8B and Figure 8C The rectangular tube 110 has four sides 112. Each side 112 of the tube 110 has an inner surface 114 and an outer surface 116. The tube 110 includes a pair of reinforcement regions 118 projecting from the inner surface 114 of each side 112, and a pair of reinforcement regions 119 projecting from the outer surface 116 of each side 112. The reinforcement regions 118, 119 extend along a length 120 of the tube 110. The tube 110 has a thickness 122 in the reinforcement regions 118, a thickness 123 in the reinforcement regions 119, and a thickness 124 in other regions of the tube 110 (e.g., the remainder of the tube 110).

[0101] The thickness 122, 123 of the tube 110 in the reinforced regions 118, 119 is greater than the thickness 124 of the tube 110 in other regions. In one example, each thickness 122, 123 of the tube 110 in the reinforced regions 118, 119 is equal to 3 mm, and the thickness 124 of the tube 110 in other regions is equal to 2.5 mm. Thus, in this example, the reinforced regions 118, 119 of the tube 110 are 0.5 mm thicker than other regions of the tube 110. Each reinforced region 118 has a width 125 (e.g., 6 mm), and each reinforced region 119 has a width 127 (e.g., 6 mm). The thickness 122, 123 of the tube 110 in the reinforced regions 118, 119, the thickness 124 of the tube 110 in other regions, and / or the width 125, 127 of the reinforced regions 118, 119 on one side 112 of the tube 110 can be equal to or different from the thickness 122, 123, the thickness 124, and / or the width 125, 127 on the other side 112 of the tube 110, respectively.

[0102] The two sides 112 of the tube 110 define a width 126 of the tube 110, and the other two sides 112 of the tube 110 define a height 128 of the tube 110. The width 126 of the tube 110 can be equal to or different from the height 128 of the tube 110. Thus, the dimensions of the sides 112 defining the width 126 of the tube 110 can be equal to or different from the dimensions of the sides 112 defining the height 128 of the tube 110. In one example, the width 126 of the tube 110 is 150 mm, and the height 128 of the tube 110 is 150 mm.

[0103] The longitudinal centerlines of the reinforced regions 118 on each side 112 of the tube 110 are spaced apart by a distance 130, and the longitudinal centerlines of the reinforced regions 119 on each side 112 of the tube 110 are spaced apart by a distance 131. The distances 130, 131 by which the longitudinal centerlines of the reinforced regions 118, 119 are spaced apart on one side 112 of the tube 110 can be equal to or different from the distances 130, 131 by which the longitudinal centerlines of the reinforced regions 118, 119 are spaced apart on the other side 112 of the tube 110. In one example, the distance 130 by which the longitudinal centerlines of the reinforced regions 118 are spaced apart on each side 112 of the tube 110 is equal to 38.5 mm, and the distance 131 by which the longitudinal centerlines of the reinforced regions 119 are spaced apart on each side 112 of the tube 110 is equal to 70 mm.

[0104] The tube 110 can be formed from metal using extrusion. The reinforced regions 118, 119 of the tube 110 can be formed integrally with the rest of the tube 110. For example, the reinforced regions 118, 119 of the tube 110 can be formed integrally with the rest of the tube 110 in a single extrusion operation.

[0105] Referring now to Figure 9A and Figure 9B A blank 132 can be cut from each side 112 of the tube 110 such that the blank 132 includes at least a portion of each reinforcement region 118, 119. In the illustrated example, each blank 132 includes a majority of the reinforcement regions 118, 119 from one side 112 of the tube 110. Additionally, each blank 132 is cut such that the reinforcement regions 118, 119 are aligned with the length 134 of the blank 132. Each blank 132 can be cut from one side 112 of the tube 110 using milling, electrical discharge machining, laser cutting, or water jet cutting. The remaining portion of the tube 110 can be recycled.

[0106] Each blank 132 can be formed into the desired shape of the vehicle door beam 136 using room temperature stamping, hot stamping, or roll forming. The vehicle door beam 136 has a hat-shaped cross-section or a u-shaped cross-section with flanges 138 protruding from the ends of the u-shaped cross-section. The vehicle door beam 136 includes a flat section 140, a flat section 142, a flat section 144, a curved section 146 connecting the flat sections 140, 142 to each other, and a curved section 148 connecting the flat sections 142, 144 to each other. The flat sections 140, 142, 144 and the curved sections 146, 148 form the u-shaped cross-section of the vehicle door beam 136. In various embodiments, a stiffening rib can be formed along the longitudinal centerline of the flat section 142, and the stiffening rib can be recessed relative to the remaining portion of the flat section 142.

[0107] The vehicle door beam 136 further includes a curved section 150 connecting one of the flanges 138 to the flat section 140, and a curved section 152 connecting the other flange 138 to the flat section 144. As best shown in Figure 9B The reinforcement regions 118, 119 are positioned on the tube 110 such that, when the blank 132 is formed into the desired shape of the vehicle door beam 136, the reinforcement regions 118 and 119 reside in the curved sections 146, 148 and 150, 152, respectively, of the vehicle door beam 136. As a result, as shown in Figure 8B and Figure 8C The thickness 124 of the tube 110 in other regions can be less than the thickness 122, 123 of the tube 110 in the reinforcement regions 118, 119 while maintaining the structural integrity of the vehicle door beam 136, as shown in

[0108] Each flat section 140, 144 of the door beam 136 is oriented at a non-zero angle 154 with respect to the flat section 142 of the door beam 136. Each flange 138 of the door beam 136 is oriented at a non-zero angle 156 with respect to the flat section 140 or 144. In the example shown, each non-zero angle 154, 156 is an obtuse angle. The flat sections 140, 142, 144 and the curved sections 146, 148, 150, 152 extend along a length 158 of the door beam 136.

[0109] Referring now to Figure 10A , Figure 10B and Figure 10C , the cylindrical tube 160 has an inner surface 162, an outer surface 164, a first end 166, a second end 168 opposite the first end 166, and a length 170 extending from the first end 166 to the second end 168. The tube 160 includes a pair of reinforced regions 172 that protrude from the outer surface 164 of the tube 160 and extend along the length 170 of the tube 160. The tube 160 has a thickness 174 in the reinforced regions 172 and a thickness 176 in other regions of the tube 160 (e.g., the remainder of the tube 160). The thickness 174 of the tube 160 in the reinforced regions 172 is greater than the thickness 176 of the tube 160 in the other regions.

[0110] The tube 160 can be formed from metal using extrusion. The reinforced regions 172 of the tube 160 can be formed integrally with the remainder of the tube 160. For example, the reinforced regions 172 of the tube 160 can be formed integrally with the remainder of the tube 160 in a single extrusion operation.

[0111] Figure 10A The tube 160 is shown after the tube 160 has been extruded, with the reinforced regions 172 extending parallel to a central longitudinal axis 178 of the tube 160. In Figure 10B , the tube 160 is twisted about its central longitudinal axis 178, and thus the reinforced regions 172 no longer extend parallel to the central longitudinal axis 178. To twist the tube 160 about its central longitudinal axis 178, the second end 168 of the tube 160 can be twisted in a direction 180 while the first end 166 of the tube 160 is held in a constant position or twisted in a direction 182 opposite the direction 180.

[0112] In Figure 10CFrom the tube 160, a blank 184 is cut such that the blank 184 includes at least a portion of each reinforcement region 170. Additionally, the blank 184 is cut such that, prior to its removal, a length 186 of the blank 184 extends parallel to the length 169 of the tube 160 and a longitudinal centerline 188 of the blank 184 is parallel to the central longitudinal axis 178 of the tube 160. Because the tube 160 is twisted about its central longitudinal axis 178 prior to cutting the blank 184, each reinforcement region 170 is misaligned (e.g., not parallel) with the length 186 of the blank 184 and misaligned with the longitudinal centerline 188 of the blank 184.

[0113] The blank 184 can be cut from the tube 160 using milling, electrical discharge machining, laser cutting, or water jet cutting. The blank 184 can be formed into a desired shape for a vehicle body structural component (such as a vehicle door beam) using room temperature stamping, hot stamping, or roll forming. Prior to cutting the blank 184, the tube 160 can be twisted about its central longitudinal axis 178 such that, when the blank 184 is formed into the vehicle body structural component, the reinforcement regions 172 extend along high stress areas of the component. As a result, the thickness 176 of the tube 160 in other areas can be less than the thickness 174 of the tube 160 in the reinforcement regions 172 while maintaining the structural integrity of the vehicle body structural component.

[0114] Referring now to Figure 11A , Figure 11B and Figure 11C , a rectangular tube 190 has four sides 192. Each side 192 of the tube 190 has an inner surface 194 and an outer surface 196. The tube 190 includes a pair of reinforcement regions 198 that protrude from the outer surface 196 of each side 192 and extend along a length 200 of the tube 190. The tube 190 has a thickness 202 in the reinforcement regions 198 and a thickness 204 in other areas of the tube 190 (e.g., the remainder of the tube 190). The thickness 202 of the tube 190 in the reinforcement regions 198 is greater than the thickness 204 of the tube 190 in the other areas.

[0115] The tube 190 can be formed from metal using extrusion. The reinforcement regions 198 of the tube 190 can be formed integrally with the remainder of the tube 160. For example, the reinforcement regions 198 of the tube 160 can be formed integrally with the remainder of the tube 160 in a single extrusion operation.

[0116] Figure 11A The tube 190 is shown after the tube 190 has been extruded, with the reinforcement regions 198 extending in straight lines parallel to the length 200 of the tube 190. In Figure 11BIn the embodiment shown in FIG. 1, the tube 190 is bent about a midline plane along the length 200 of the tube 190, and thus the reinforcement region 198 is curved or nonlinear (e.g., no longer extends in a straight line). The tube 190 can be bent about a mandrel (not shown) by pressing a ram (not shown) against the tube 190 in the direction 206 while holding both ends of the tube 190. In various embodiments, the tube 190 can be bent about a plane located at a position other than the midline. Additionally or alternatively, multiple bends can be made in the tube 190 to, for example, form the tube 190 into an S-shape.

[0117] In Figure 11C In the embodiment shown in FIG. 1, the tube 190 is bent about a midline plane along the length 200 of the tube 190, and thus the reinforcement region 198 is curved or nonlinear (e.g., no longer extends in a straight line). The tube 190 can be bent about a mandrel (not shown) by pressing a ram (not shown) against the tube 190 in the direction 206 while holding both ends of the tube 190. In various embodiments, the tube 190 can be bent about a plane located at a position other than the midline. Additionally or alternatively, multiple bends can be made in the tube 190 to, for example, form the tube 190 into an S-shape.

[0118] Referring now to Figure 12A and Figure 12B The rectangular tube 210 has four sides 212. Each side 212 of the tube 210 has an inner surface 214 and an outer surface 216. The tube 210 includes a pair of reinforcement regions 218 that protrude from the outer surface 216 of each side 212 and extend along the length 220 of the tube 210. The tube 210 has a thickness 222 in the reinforcement regions 218 and a thickness 224 in other regions of the tube 210 (e.g., the remainder of the tube 210). The thickness 222 of the tube 210 in the reinforcement regions 218 is greater than the thickness 224 of the tube 210 in the other regions.

[0119] The tube 210 can be formed from metal using extrusion. The reinforcement regions 218 of the tube 210 can be formed integrally with the remainder of the tube 160. For example, the reinforcement regions 218 of the tube 160 can be formed integrally with the remainder of the tube 160 in a single extrusion operation.

[0120] Figure 12A The tube 210 is shown after the tube 210 has been extruded, with the reinforcement regions 218 extending parallel to the length 220 of the tube 210. In Figure 12BFrom the tube 210, a blank 226 can be cut such that the blank 226 includes at least a portion of each reinforcement region 218 and such that the reinforcement regions 218 are misaligned with the length 228 of the blank 226. The blank 226 can be cut from the tube 210 using milling, electrical discharge machining, laser cutting, or water jet cutting. The blank 226 can be formed into a desired shape for a vehicle body structural component (such as a vehicle door beam) using room temperature stamping, hot stamping, or roll forming. The blank 226 can be cut such that the reinforcement regions 218 are misaligned with respect to the length 220 of the tube 210 such that, when the blank 226 is formed into a vehicle body structural component, the reinforcement regions 218 extend along high stress regions of the component. As a result, the thickness 224 of the tube 210 in other regions can be less than the thickness 222 of the tube 210 in the reinforcement regions 218 while maintaining the structural integrity of the vehicle body structural component.

[0121] The foregoing description is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. The broad teachings of the disclosure can be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be limited to such examples. The methods and systems of the disclosure will find use in a variety of applications. Further, although the examples provided herein are primarily taught with reference to particular program code implementations, it will be appreciated that those of ordinary skill in the art will be able to make and use modifications and variations without the

[0122] Spatial and functional relationships between elements (for example, between modules, circuit elements, semiconductor layers, etc.) are described using various terms, including "connected," "engaged," "coupled," "adjacent," "next to," "on," "above," "below," and "disposed." Unless explicitly described as being "direct," a relationship between a first and a second element described in the above disclosure can also be an indirect relationship in which one or more other intervening elements are present (spatially or functionally) between the first and second elements.

[0123] Spatially relative terms can be intended to encompass different orientations of the device in use or operation in addition to the orientations depicted in the figures. For example, if a device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the example term "below" can encompass both an orientation of above and below. The device can be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0124] Although the terms first, second, third, etc. can be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms can be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as "first," "second," and other numerical terms when used herein do not connote a sequential or chronological order, unless explicitly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of example embodiments.

[0125] As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C) using the non- exclusive logical OR, and it should not be construed to mean "at least one of A, and at least one of B, and at least one of C."

Claims

1. A method of manufacturing a vehicle body structure component, the method comprising: extruding a tube to include at least one reinforcement region extending along a length of the tube, the tube having a first thickness in the at least one reinforcement region and a second thickness in other regions of the tube, wherein the first thickness is greater than the second thickness, wherein the at least one reinforcement region includes a pair of first reinforcement regions protruding from an outer surface of the tube and a pair of second reinforcement regions protruding from an inner surface of the tube; cutting a blank from the tube such that the blank includes at least a portion of the at least one reinforcement region; and forming the blank into a desired shape of the component.

2. The method of claim 1, wherein, the tube is a rectangular tube having four sides, the method further comprising: extruding the tube to include the at least one reinforcement region on each side of the tube.

3. The method of claim 2, wherein, the at least one reinforcement region includes a pair of reinforcement regions protruding from an outer surface of the tube.

4. The method of claim 2, wherein, the at least one reinforcement region includes a pair of reinforcement regions protruding from an inner surface of the tube.

5. The method of claim 1, wherein, the first reinforcement regions are spaced apart from each other by a first distance and the second reinforcement regions are spaced apart from each other by a second distance, the second distance being less than the first distance.

6. The method of claim 1, wherein, the component includes a first flat section, a second flat section oriented at a non-zero angle relative to the first flat section, and a curved section connecting the first and second flat sections to each other, the method further comprising: positioning the at least one reinforcement region on the tube such that, when the blank is formed into the desired shape of the component, at least one reinforcement region resides in the curved section.

7. The method of claim 6, wherein, the first flat section, the second flat section, and the curved section extend along a length of the component.

8. The method of claim 1, wherein, the tube is a cylindrical tube, the method further comprising: twisting the tube prior to cutting the blank from the tube such that the at least one reinforcement region is not aligned with a length of the blank.

9. The method of claim 1, wherein, the tube is a rectangular tube, the method further comprising: bending the tube prior to cutting the blank from the tube such that the at least one reinforcement region is non-linear.

10. The method of claim 1, further comprising: cutting the blank from the tube such that the at least one reinforcement region is not aligned with a length of the blank.

11. A method of manufacturing a vehicle body structure component, the method comprising: extruding a rectangular tube to include at least one pair of reinforcement regions on each side of the tube, the at least one pair of reinforcement regions extending along a length of the tube, the tube having a first thickness in the reinforcement regions and a second thickness in other regions of the tube, wherein the first thickness is greater than the second thickness, wherein the at least one pair of reinforcement regions includes a first pair of reinforcement regions protruding from an outer surface of the tube and a second pair of reinforcement regions protruding from an inner surface of the tube; cutting a blank from the tube on each side of the tube such that the blank includes at least a portion of the at least one pair of reinforcement regions; and forming the blank into a desired shape of the component having a u-shaped cross-section with flanges protruding from ends of the u-shaped cross-section.

12. The method of claim 11, wherein, The component includes a first flat section, a second flat section, a third flat section, a first curved section connecting the first flat section and the second flat section to each other, and a second curved section connecting the second flat section and the third flat section to each other, the first flat section, the second flat section, and the third flat section, and the first curved section and the second curved section forming the u-shaped cross-section.

13. The method of claim 12, further comprising: The at least one pair of reinforcement regions is positioned on the tube such that, when the blank is formed into the desired shape of the component, the at least one pair of reinforcement regions resides in the first curved section and the second curved section of the component.

14. The method of claim 12, wherein, The component further includes a third curved section connecting one of the flanges to the first flat section, and a fourth curved section connecting the other of the flanges to the third flat section.

15. The method of claim 14, further comprising: The at least one pair of reinforcement regions is positioned on the tube such that, when the blank is formed into the desired shape of the component, the at least one pair of reinforcement regions resides in the third curved section and the fourth curved section of the component.

16. The method of claim 14, wherein, The method further includes positioning the first pair of reinforcement regions and the second pair of reinforcement regions on the tube such that, when the blank is formed into the desired shape of the component, the first pair of reinforcement regions resides in the first curved section and the second curved section of the component, and the second pair of reinforcement regions resides in the third curved section and the fourth curved section of the component.

17. The method of claim 11, wherein, The second thickness of the tube on one side thereof is different than the second thickness of the tube on another side thereof.

18. The method of claim 11, further comprising: The at least one pair of reinforcement regions is placed on one side of the tube in one manner, and the at least one pair of reinforcement regions is placed on another side of the tube in a different manner.

19. The method of claim 11, further comprising: The tube is extruded such that the tube has a width and a height that is different than the width.

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