Method for producing integral body side structural frame of vehicle

Abstract

A method for manufacturing an integral body side structural frame of a vehicle. The method comprises the following steps: providing a plurality of blanks; bonding the blanks to each other to form a composite blank, wherein bonding the blanks includes forming one or more overlapping regions formed by partially overlapping the two blanks; deforming the composite blank to form an integral body side structural frame; wherein the integral vehicle body side structural frame includes: a lower beam portion including a sill portion; an upper beam portion; and a front pillar portion and a rear pillar portion connecting the lower beam portion to the upper beam portion, in which the integral body side structural frame includes a B pillar portion in which one of the overlapping regions is included within the sill portion and corresponds to a transition region between the sill portion and the B pillar portion, wherein the unitary body side structural frame is configured to be attached to a lower flange of an inner or outer panel of the sill such that a gap is provided between a transition between the sill portion and the B-pillar portion and an upper flange of the inner or outer panel.

Description

[0001] This application is a divisional application of the Chinese national phase patent application with international application number PCT / EP2019 / 066846, international application date June 25, 2019, and invention name “Vehicle body side structural frame”, which entered the Chinese national phase on February 4, 2021 and has application number 201980051946.1.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims the benefit of and priority to EP 18 382 467.1 filed on June 25, 2018. Technical Field

[0004] The present disclosure relates to a body side structural frame of a vehicle and a method of manufacturing the body side structural frame of a vehicle. Background Art

[0005] Vehicles, such as cars, contain a structural frame designed to withstand all loads to which the vehicle is subjected during its service life. The structural frame is further designed to withstand and absorb impacts in the event of, for example, a collision with another car or an obstacle.

[0006] The structural framework of a vehicle (e.g., a car) in this sense may include, for example, bumpers, pillars (A-pillars, B-pillars, C-pillars, D-pillars), side impact beams, sills or lower side beams, hinge pillars, and shock absorbers. The body side structural frame typically includes a rocker panel, a hinge pillar, an A-pillar, and a B-pillar. The body side structural frame may further include a C-pillar and a D-pillar.

[0007] In some examples, the body side structural frame may be formed by connecting multiple structural components around the door, for example, by connecting the lower portion of a previously formed B-pillar to a previously formed door sill and connecting the upper portion of the B-pillar to the previously formed A-pillar and / or C-pillar; and connecting the lower portion of a previously formed hinge pillar to the door sill and connecting the upper portion of the hinge pillar to the A-pillar and / or C-pillar.

[0008] Such structural members may be formed by one or more plates that are combined with each other. For example, a B-pillar may be formed by a central reinforcement B-pillar, an inner plate, and in some examples, an outer plate. The central reinforcement, the inner plate, and the outer plate may be combined at their side flanges. The B-pillar, A-pillar, C-pillar, and other structural members may be supplied to the vehicle manufacturer, for example, by a single or different supplier in order to combine them to form a body side structural frame.

[0009] In other examples, the body side structural frame may be prepared as a unitary structure and then supplied to a vehicle manufacturer. According to this aspect, the body side structural frame may be formed by combining different blanks (e.g., by welding) to form a composite blank and then shaping the composite blank (e.g., by hot forming or cold forming).

[0010] An example of this type of integral body side structural frame and its manufacturing method can be found in US2006 / 0097549A1. This document describes a side panel of a motor vehicle, which includes: a bottom side beam member, a top panel portion, and a plurality of pillars extending between the side beam member and the top panel portion. The side beam member of this document is formed of a monolithic structure with the pillars and the top panel portion by a sheet metal blank made of high-strength steel and has at least one area that is partially hardened and is subjected to increased loads in the event of a collision with a motor vehicle.

[0011] Welding different blanks to form a composite blank and then shaping the composite blank is generally referred to as a tailor welded blank (TWB). Blanks of different thicknesses, sizes, materials or properties can be combined to form a composite blank for the purpose of minimizing the weight of the component while complying with structural requirements. The blanks are welded "edge to edge" ("butt joint").

[0012] These so-called custom blanks are usually designed to be hot stamped and then manufactured to form automotive parts (such as body side structural frames). In addition, such custom blanks can also be designed to be cold formed. Hot forming die quenching (HFDQ) uses boron steel sheets to form stamped parts with ultra-high strength steel (UHSS) properties, with a tensile strength of at least 1.000 MPa (preferably about 1.500 MPa or up to 2.000 MPa or more).

[0013] An example of a steel used in the hot stamping process is 22MnB5 steel. 22MnB5 steel is supplied in a ferrite-pearlite phase. The mechanical properties are related to this structure. After heating, the blank is hot formed and can then be subsequently quenched. This process is known as press hardening. With this process, a microstructure that is mainly martensitic can be formed. As a result, the ultimate tensile strength and yield strength are significantly increased.

[0014] 1500P is an example of 22MnB5 steel. The composition is summarized as follows in weight percentage (the rest is iron (Fe) and unavoidable impurities):

[0015]

[0016] 1500P may have, for example, a yield strength of 1.100 MPa and an ultimate tensile strength of 1.500 MPa.

[0017] 2000 is another boron steel with even higher strength. The yield strength of 2000 may be 1.400 MPa or more, and the ultimate tensile strength may be higher than 1.800 MPa. The composition of 2000 includes a maximum of 0.37 weight percent carbon, a maximum of 1.4 weight percent magnesium, a maximum of 0.7 weight percent silicon, and a maximum of 0.005 weight percent boron.

[0018] Various other steel compositions of UHSS may also be used in the automotive industry. In particular, the steel compositions described in EP2735620A1 may be considered suitable. Reference may be made specifically to Table 1 and paragraphs 0016-0021 of EP2735620A1, and to paragraphs 0067-0079.

[0019] In some examples, the UHSS blank may include approximately 0.22 weight percent carbon, 1.2 weight percent silicon, and 2.2 weight percent magnesium.

[0020] In some other examples, the UHSS blank may include 0.17-0.23 weight percent carbon, up to 2.5 weight percent magnesium, up to 0.5 weight percent silicon, and 0.002-0.005 weight percent boron.

[0021] Another material used in hot stamping is 500. 500 is a steel material with much higher ductility, and this can be effective for absorbing energy during impact. The yield strength of 500 may be 400 MPa or more, and its ultimate tensile strength is 550 MPa or more.

[0022] The composition of 500 includes up to 0.1% carbon, up to 1.3% magnesium, up to 0.5% silicon and up to 0.001% boron.

[0023] 1000 is used for hot stamping to 1500 and 2000 compared to another material with increased elongation. The yield strength of 1000 may be 800 MPa or more, and its ultimate tensile strength is 1000 MPa or more. The composition of 1000 includes up to 0.12% carbon, up to 2% magnesium, up to 0.75% silicon, and up to 0.005% boron.

[0024] In order to avoid decarburization and scale formation during the forming process and to prevent corrosion and oxidation damage, steels of any of these compositions (e.g. 22MnB5 steels such as and other components mentioned or referenced above) are presented in the form of a coating. The coating can be, for example, an aluminum-silicon (AlSi) coating or a coating mainly containing zinc or a zinc alloy.

[0025] However, aluminum-silicon coatings have significant drawbacks related to their welding properties. If blanks with aluminum-silicon coatings are welded to form tailor-welded blanks (TWBs) without any additional measures, the aluminum in the coating can enter the weld area and this can lead to a significant reduction in the mechanical properties of the resulting component and increase the likelihood of fractures in the weld zone.

[0026] In order to overcome this problem, it is known to remove a portion of the coating in the area close to the welding zone, for example by laser ablation. This method has the following disadvantages: an additional step is required for the preparation of (custom or composite) blanks and components and, despite the reproducibility of the process, this additional step requires a complex quality process in which an increased number of parts are scrapped. This increases the costs of the welding step and limits the competitiveness of this technology in the industry.

[0027] Recently, other methods have been developed to avoid the step of ablating the coating. However, such methods require the use of additional powders or wires to resist the presence of aluminum throughout the weld zone.

[0028] After forming the integral body side structural frame, the integral body side structural frame can be joined (e.g., welded) to the remainder of the structural skeleton of the vehicle, such as the inner panel of at least one of the A-pillar, the B-pillar, the C-pillar, the hinge pillar, and the rocker. For example, the lower portion of the integral body side structural frame can be connected to the lower flange of the inner panel of the rocker, and the upper portion of the integral body side structural frame can be connected to the upper flange of the inner panel of the A-pillar and / or the C-pillar. The integral body side structural frame formed in this manner can therefore correspond to an "outer" panel that can be complementary to the inner panel of the A-pillar, the inner panel of the B-pillar, the inner panel of the C-pillar, the inner panel of the hinge pillar, and / or the inner panel of the rocker.

[0029] However, with this method, some sections of the A-pillar are not completely enclosed. The lower flange of the inner panel of the A-pillar and the integral body side structural frame are not assembled together along their entire length, that is, there is a gap in some sections of the A-pillar. This may occur in the area where the A-pillar is substantially behind the B-pillar (especially behind the central part of the B-pillar) (that is, in the area corresponding to the U-shaped section of the B-pillar). Similarly, the upper flange of the inner panel of the door sill and the body side structural frame are not in contact along the entire length of the door sill. This may occur in the area where the door sill is substantially behind the B-pillar and / or the hinge pillar, and therefore some sections of the door sill may also not be completely enclosed.

[0030] According to these aspects, there are some sections in the A-pillars and / or the sills that are not completely closed (i.e. they do not form a closed section with their corresponding inner panel). Such sections may therefore have less strength when compared to a solution in which the inner and outer panels are welded along their entire length by both upper and lower flanges (i.e. in which the pillars and sills are first deformed and then assembled to the rest of the structural skeleton of the vehicle). Such sections with less strength may lead to reduced structural performance of the vehicle in the event of a collision. However, in order to ensure good functional performance of the side structural frame relative to the door, and due to the characteristics of the geometric environment of the body side structural frame, it may be difficult to provide a completely closed section between the side structural frame and the inner panel (or panels) along the entire section while ensuring, for example, the proper position of the rubber seal of the body side structural frame.

[0031] The present disclosure provides examples of systems and methods that at least partially address some of the aforementioned shortcomings. Summary of the invention

[0032] In a first aspect, a method for manufacturing an integral body side structural frame of a vehicle is provided. The method includes providing a plurality of blanks; combining the blanks to form a composite blank, wherein combining the blanks includes forming one or more overlapping regions formed by overlapping at least two blank portions; deforming the composite blank to form the integral body side structural frame; and wherein the integral body side structural frame includes a lower beam portion and an upper beam portion, a front pillar portion connecting the lower beam portion to the upper beam portion, and a rear pillar portion connecting the lower beam portion to the upper beam portion.

[0033] According to this aspect, the thickness of some areas of the integral body side structural frame is increased, and thus the strength of the integral body side structural frame can also be increased. Compared with a solution in which the overall thickness of one of the blanks is increased, the increase in thickness in one or more overlapping areas can reduce the overall weight of the integral body side structural frame and the number of welds.

[0034] In the present disclosure, partially overlapping two blanks means that only a portion of the two blanks overlap.

[0035] The lower beam portion may be a door sill portion. The upper beam portion may extend parallel to the roof of the vehicle. The front pillar portion and the rear pillar portion may extend substantially vertically from the lower beam portion to the upper beam portion. The integral body side structural frame may thus define a door opening of a front door opening and / or a rear door opening and / or a door opening including both a rear door opening and a front door opening. Such an integral body side structural frame may also be referred to as a "single-piece door ring" or "integrated door ring".

[0036] In the present disclosure, the door sill, A-pillar, B-pillar, C-pillar and hinge pillar should be understood as follows. The door sill or side beam is a component arranged in a generally horizontal direction and extending from the rear to the front of the vehicle below the (one or more) door openings. The B-pillar is a vertically arranged component extending from the door of the vehicle to the roof. The B-pillar is arranged in the central area of ​​the vehicle and usually separates the front door opening and the rear door opening. The hinge pillar is a vertical body extending generally from the door to the hood or windshield of the vehicle. The hinge of the front door is usually mounted on the hinge pillar. The A-pillar is an arched body extending generally parallel to a portion of the top panel and a portion of the front windshield in the upper area of ​​the door opening. The A-pillar extends from the upper part of the B-pillar to the upper part of the hinge pillar. In some configurations, the A-pillar can extend beyond the B-pillar. The C-pillar is a structure located behind the rear door of the vehicle that extends upward from the door sill portion. In some examples, it can extend from the door sill to the A-pillar (when the A-pillar extends beyond the B-pillar) in a generally vertical direction. In other examples, the C-pillar may include a generally vertical portion and an arched portion that extend generally parallel to a portion of the roof panel and an upper region of the rear door opening to intersect the B-pillar.

[0037] In some examples, the B-pillar, A-pillar, hinge pillar, and door sill may define a door frame, and may thus form an integral body side structural frame of the front door opening.

[0038] In other examples, a unitary body side structural frame may be formed by connecting a lower portion of a B-pillar to a rocker, an upper portion of a B-pillar to an upper portion of a C-pillar, and a lower portion of a C-pillar to the rocker so that a frame for a rear door opening is formed.

[0039] In other examples, the unibody side structural frame can surround both the front door opening and the rear door opening of the vehicle. In these examples, the door sill can be connected to the hinge pillar and the C-pillar, and the A-pillar can connect the hinge pillar to the C-pillar. In some of these examples, the unibody side structural frame can further include a B-pillar.

[0040] In all of these examples, the integral body side structural frame may be an outer frame. The integral outer body side structural frame may thus be joined to the remainder of the structure of the vehicle. Alternatively, the integral body side structural frame may be an inner frame. Such an integral inner frame may be joined to the outer frame.

[0041] When the body side structural frame is formed as a unitary structure, the boundaries between the different pillars become less clear, precisely because it is a single structure. Therefore, reference is made herein to a B-pillar "portion", an A-pillar "portion", a C-pillar "portion", etc. to identify portions of the B-pillar, A-pillar, C-pillar, etc. that may be considered to form a unitary structure.

[0042] The transition zone between the beam portion and the column portion is the area where the column portion intersects the beam portion, or in other words, the area that changes from a generally horizontally arranged body to a generally vertical body. As a result, the transition zone between the B-pillar portion and the rocker portion is the area where the B-pillar portion intersects the rocker portion, that is, the area that changes from a generally horizontally arranged body to a generally vertical body. The transition zone between the A-pillar portion and the B-pillar portion, the transition zone between the A-pillar portion and the hinge pillar portion, and the transition zone between the hinge pillar portion and the rocker portion can be similarly defined. Similarly, the transition zone between the C-pillar portion and the A-pillar portion, the transition zone between the C-pillar portion and the B-pillar portion, and the transition zone between the C-pillar portion and the rocker portion can also be defined.

[0043] The one or more overlap regions may be arranged to counteract material reduction and resulting strength reduction that may occur in some sections of the integral side body structural frame when compared to a solution in which structural components are formed first and then joined to form the body side structural frame.

[0044] In some examples, at least one of the (one or more) overlapping regions may generally correspond to a transition zone between a beam portion (e.g., a lower beam portion or an upper beam portion) and a pillar portion (e.g., a front pillar portion or a rear pillar portion of a monolithic structural frame). That is, one overlapping region may correspond to a transition zone between a rear pillar portion (e.g., a B-pillar portion or a C-pillar) and a lower beam portion (e.g., a rocker portion); or to a transition zone between a rear pillar portion and an upper beam portion; or to a transition zone between a front pillar portion (e.g., a hinge pillar or a B-pillar) and a lower beam portion or between a front pillar portion and an upper beam portion.

[0045] Alternatively, or in addition, the overlap can be arranged in a location where high loads are expected. For example, the overlap can be arranged in a beam portion and / or a column portion. In some of these examples, at least one of the overlapping areas can be arranged in an upper beam portion, such as in an A-pillar portion or in a C-pillar portion.

[0046] In some examples, the blanks can be combined to each other including welding the blanks to each other in the overlapping area. By combining the blanks to each other in the overlapping area, it is not necessary to remove the portion of the coating in the area near the welding zone or to use powder or wire material. As a result, the efficiency of the manufacturing process can be improved, and the cost can be reduced. Optionally, welding these blanks can include spot welding. In other examples, alternative welding techniques can be used, such as remote laser welding. In other examples, the blanks can be combined by other suitable methods (e.g., by glue).

[0047] In some examples, the integral body side structural frame may be a front frame. In these examples, the lower beam portion may include a rocker portion, the upper beam portion may include an A-pillar portion, the front pillar portion may include a hinge pillar portion, and the rear pillar portion may include a B-pillar portion.

[0048] One or more overlapping regions may be arranged in regions of the integral side structural frame that are subject to high loads in the event of a lateral collision, for example in the transition between the B-pillar and the sill and / or in the transition between the B-pillar and the A-pillar.

[0049] In some of these examples, one of the overlapping regions may generally correspond to the transition region between the rocker portion and the B-pillar portion, i.e., the region changing from a generally horizontal arrangement to a generally vertical arrangement. In this way, the strength loss caused by the gap formed between the inner panel of the rocker and the bottom section of the U-shaped section of the B-pillar may be compensated by the thickness increase provided by the overlapping region. Thus, the portion of the monocoque body side structural frame extending from the rocker portion to the B-pillar portion is reinforced.

[0050] Alternatively or additionally, one of the overlapping regions may substantially correspond to a transition zone between the B-pillar portion and the A-pillar portion. As a result, a portion of the integral body side structural frame extending from the B-pillar portion to the A-pillar portion is strengthened.

[0051] In some examples, one of the overlapping regions may generally correspond to a transition zone between the A-pillar portion and the hinge pillar portion. Such an overlapping region may provide additional rigidity to the structural frame, particularly in the portion extending from the hinge portion to the A-pillar portion.

[0052] One of the overlapping regions may also generally correspond to a transition area between the rocker portion and the hinge portion.

[0053] Additionally or alternatively, one of the overlapping regions may be arranged in the A-pillar portion.

[0054] The integral body side structural frame may include several overlapping regions. For example, the B-pillar portion may include one overlapping region arranged on its lower portion (i.e., arranged in the transition region between the rocker portion and the B-pillar portion) and another overlapping region arranged on its upper portion (i.e., arranged in the transition region between the B-pillar and the A-pillar). The rigidity of the B-pillar portion and thus the rigidity of the entire integral body side structural frame may thus be increased.

[0055] In some other examples, the integral body side structural frame may be a rear frame. In these examples, the front pillar portion includes a B-pillar portion, the lower beam portion may include a rocker portion, and the upper beam portion and the rear pillar portion may include a C-pillar portion extending from the rocker portion to the B-pillar portion.

[0056] In some of these examples, one of the overlapping regions may generally correspond to a transition area between the rocker portion and the B-pillar portion.

[0057] Alternatively or additionally, one of the overlapping regions may generally correspond to a transition region between the B-pillar portion and the C-pillar portion.

[0058] In further examples, one of the overlapping regions may also generally correspond to a transition area between the C-pillar portion and the rocker portion.

[0059] In some other examples, the integral body side structural frame may be a frame of a single opening surrounding both the front door and the rear door of the vehicle. In these examples, the lower beam portion may include a rocker portion, the front pillar portion may include a hinge pillar portion, the rear pillar portion may include a C-pillar portion, and the rear beam portion may include an A-pillar portion. The A-pillar portion may thus extend from the hinge pillar portion to the C-pillar portion, and the C-pillar portion may thus extend from the rocker portion to the A-pillar portion.

[0060] In the present disclosure, the B-pillar-sill overlap region shall be understood as the overlap region substantially corresponding to or disposed in the transition region between the B-pillar portion and the sill portion; the A-pillar-B-pillar overlap region shall be understood as the overlap region substantially corresponding to or disposed in the transition region between the A-pillar portion and the B-pillar portion; the A-pillar-hinge overlap region shall be understood as the overlap region substantially corresponding to or disposed in the transition region between the A-pillar portion and the hinge pillar portion; the hinge-sill overlap region shall be understood as the overlap region substantially corresponding to or disposed in the transition region between the hinge pillar portion and the sill portion; the C-pillar-sill overlap region shall be understood as the overlap region substantially corresponding to or disposed in the transition region between the hinge pillar portion and the sill portion; The term "overlapping area" shall be understood as the overlapping area that generally corresponds to or is arranged in the transition zone between the C-pillar portion and the rocker portion; the C-pillar-B-pillar overlapping area shall be understood as the overlapping area that generally corresponds to or is arranged in the transition zone between the C-pillar portion and the B-pillar portion; the C-pillar-A-pillar overlapping area shall be understood as the overlapping area that generally corresponds to or is arranged in the transition zone between the C-pillar portion and the A-pillar portion; the B-pillar overlapping area shall be understood as the overlapping area arranged in the B-pillar portion, the A-pillar overlapping area shall be understood as the overlapping area arranged in the A-pillar, and the C-pillar overlapping area shall be understood as the overlapping area arranged in the C-pillar.

[0061] In the present disclosure, the length of the overlapping area should be understood as the distance along the longitudinal axis of the beam portion (e.g., the A-pillar portion or the door sill portion) that is part of the overlapping area. The longitudinal axis of the beam portion that is part of the overlapping area can correspond to the longitudinal axis of the vehicle, i.e., from the rear crossbar to the front crossbar. The height of the overlapping area is generally perpendicular to its length and should be understood as the distance along the longitudinal axis of the front pillar portion or the rear pillar portion (e.g., the longitudinal axis of the B-pillar portion or the hinge pillar portion or the C-pillar portion) that is part of the overlapping area. The height of the overlapping area can generally correspond to the vertical axis of the vehicle, i.e., from the bottom of the vehicle to the roof. The length and / or height of the overlapping area can vary along the overlapping area.

[0062] The B-pillar-sill overlap region may have a length (distance along the longitudinal axis of the sill) between 20 mm and 600 mm, preferably between 100 mm and 500 mm, and more preferably between 200 mm and 400 mm, and a height (distance along the longitudinal axis of the B-pillar) between 20 mm and 600 mm, preferably between 100 mm and 500 mm, and more preferably between 200 mm and 400 mm. The C-pillar-sill overlap region, the hinge-sill overlap region, and the A-pillar-B-pillar overlap region may have similar sizes to the B-pillar-sill overlap region.

[0063] The length (distance along the longitudinal axis of the A-pillar portion) of the A-pillar overlap region may be between 20 mm and 600 mm, preferably between 40 mm and 400 mm, and the height (distance along the longitudinal axis of the hinge pillar portion) may be between 20 mm and 600 mm, preferably between 40 mm and 300 mm. The length (distance along the longitudinal axis of the A-pillar portion) and the height (distance along the longitudinal axis of the hinge pillar portion) of the C-pillar-A-pillar overlap region may be similar to the length and height of the A-pillar-hinge overlap region.

[0064] The A-pillar overlap region may have a length (distance along the longitudinal axis of the A-pillar portion) between 20 mm and 600 mm, preferably between 40 mm and 400 mm, and a height (distance perpendicular to the length) between 20 mm and 600 mm, preferably between 40 mm and 400 mm.

[0065] The B-pillar overlap region may have a height (distance along the longitudinal axis of the B-pillar portion) between 20 mm and 600 mm, preferably between 40 mm and 300 mm, and a length (distance perpendicular to the longitudinal axis of the B-pillar portion) between 20 mm and 400 mm, preferably between 40 mm and 200 mm.

[0066] The C-pillar overlap region may have a length (distance along the longitudinal axis of the C-pillar portion) between 20 mm and 600 mm, preferably between 40 mm and 300 mm, and a height (distance perpendicular to the length) between 20 mm and 400 mm, preferably between 40 mm and 200 mm.

[0067] The integral vehicle body side structural frame is formed by combining a plurality of blanks. At least two blanks are combined with each other through one overlap region among a plurality of overlap regions. Therefore, the integral vehicle body side structural frame may include at least two blanks, for example, four blanks.

[0068] In some examples, the portion may comprise more than one blank. For example, a B-pillar portion may be formed from two or three blanks.

[0069] The integral body side structural frame may include a joint between at least two blanks with an overlapping area. The joint with the overlapping area between the two blanks may be welded by spot welding or other welding or bonding techniques. Welding the two blanks in the overlapping area to form the integral body side structural frame may increase the production efficiency of the welding process. Thus, a dimensional gap between the blanks that would otherwise occur if the blanks were not welded through the overlapping area (e.g., in a butt-bonded welding configuration) may be avoided. Accordingly, the joint with the overlapping area may help to absorb blanks of different tolerances.

[0070] In some examples, a unitary body side structural frame may include a joint between two blanks having an overlap area and other joints having an edge-to-edge configuration (eg, a square butt joint).

[0071] In some examples, deforming the composite blank to form the integral body side structural frame includes hot forming the composite blank. At least some of the blanks may be made of ultra-high strength steel (UHSS). Boron steel (e.g., 22MnB5) or other steel compositions mentioned or referenced above may be suitable UHSS. The blanks (e.g., boron steel blanks) may include an aluminum silicon coating or a zinc coating.

[0072] In some examples, hot forming may include heating the composite blank to above the austenitizing temperature, cooling the composite blank to a temperature, for example, between 400°C and 600°C, and then forming the composite blank to produce an integral body side structural frame. In some examples, forming may include two or more forming steps. These forming steps may include, for example, forming, shearing or cutting, and may be performed in a single multi-stage press. Examples of forming including two or more forming steps may be found in US9,492,859B2 and WO 2016142367A1.

[0073] Alternatively, the composite blank may be deformed by cold forming.High strength steel or ultra high strength steel may be used to form the integral body side structural frame by cold forming.

[0074] The multiple blanks forming the composite blank may comprise different materials and / or thicknesses. The blank (for example 1500 or 2000) and Blanks or parts of blanks (such as 500 or 1000). Using these types of materials in the thermoforming process results in The main martensitic structure in the part and The main ferrite structure in the component. Based on these aspects, the properties of the monocoque side structural frame can be tailored.

[0075] In a further aspect, there is provided an integral body side structural frame as obtained by a method according to any one of the examples described herein.

[0076] In some examples, the integral body side structural frame can include regions with different tensile strengths according to any of the examples described herein. In some of these examples, the regions with different tensile strengths can have different microstructures.

[0077] In some examples, at least one of the blanks may include regions with different tensile strengths. The blank may be composed of two different materials with different tensile strengths. The ductility of the region with lower tensile strength is correspondingly higher, and thus the energy absorption during a collision may be increased.

[0078] Alternatively, these regions with different tensile strengths may have different microstructures. Different microstructures may be produced in a hot-formed integral body side structural frame. These different microstructures may be produced by heating the composite blank to above the austenitizing temperature and then controlling the cooling of the composite blank during the forming of the composite blank to form the body side structural frame. The cooling of different regions of the composite blank may be controlled by providing a heater for the forming tool zone. Accordingly, the integral body side structural frame includes a region having a predominantly martensitic structure and a region containing ferrite, pearlite, bainite or a mixture thereof. Alternatively, different microstructures may be formed by, for example, locally heating a portion of the integral body side structural frame using a laser beam, which has been press-hardened to transform a predominantly martensitic structure into a structure containing ferrite and / or pearlite and / or bainite and / or tempered martensite and a mixture thereof. The tensile strength of the predominantly martensitic structure may be above 1400 MPa, and preferably above 1500 MPa, whereas the regions of lower strength may have a tensile strength below 1000 MPa, preferably below 800 MPa, such as between 800 MPa and 500 MPa. BRIEF DESCRIPTION OF THE DRAWINGS

[0079] Non-limiting examples of the present disclosure will be described below with reference to the accompanying drawings, in which:

[0080] Figure 1 An example of an integral body side structural frame of a vehicle according to the related art is shown.

[0081] Figure 2 Schematically represents the Figure 1 A cross-sectional view of the integral vehicle body side structure frame taken along line AA'.

[0082] Figure 3 An example of a unitary body side structural frame of a vehicle is shown.

[0083] Figure 4 Schematically represents the Figure 3 A cross-sectional view of the integral vehicle body side structure frame taken along line AA'.

[0084] Figure 5 is shown in being deformed to form Figure 3 Composite blank before the integral body side structural frame.

[0085] Fig. 6A Another example of a unitary body side structural frame for a vehicle is shown.

[0086] Figure 6B Another example of a unitary body side structural frame for a vehicle is shown.

[0087] Figure 7 Another example of a unitary body side structural frame for a vehicle is shown.

[0088] Figure 8A-8B An example of an integral body side structural frame coupled to an A-pillar panel and a rocker panel is shown.

[0089] Fig. 9 Another example of a unitary body side structural frame for a vehicle is shown.

[0090] Fig.10 Another example of a unitary body side structural frame for a vehicle is shown.

[0091] Fig.11 Another example of a unitary body side structural frame for a vehicle is shown. DETAILED DESCRIPTION

[0092] In these drawings, the same reference numerals have been used to identify corresponding elements.

[0093] Figure 1 An example of an integral body side structural frame 1 of a vehicle according to the prior art is shown. The body side structural frame 1 includes a rocker portion 3, an A-pillar portion 5, a hinge pillar portion 4 connecting the rocker portion 3 to the A-pillar portion 5, and a B-pillar portion 2 connecting the rocker portion 3 to the A-pillar portion 5. The hinge pillar portion 4 is located at the front of the vehicle, and the B-pillar is located at the center portion relative to the longitudinal axis of the vehicle.

[0094] The body side structural frame 1 is prepared from two blanks: a first blank 10 and a second blank 20. The blanks are joined to each other by welding along a laser welding line 19. The blanks are welded "edge to edge" (e.g., square butt joint). The blanks are first welded to form a composite blank, and then the composite blank is deformed to form the integral body side structural frame 1. Thus, the first blank 10 and the second blank 20 have been previously assembled and then deformed simultaneously in a combined forming process.

[0095] Although in Figure 1 It is not visible in the figure, but it should be understood that the integral body side structural frame 1 is joined to the rest of the structural frame of the vehicle. Figure 1 In the embodiment, the rocker portion 3 is joined to the inner panel of the rocker of the vehicle (in Figure 1), and the A-pillar portion 5 is joined to the inner panel of the A-pillar of the vehicle ( Figure 1 (not visible in the image).

[0096] Figure 2 Schematically represents the Figure 1 The sectional view of the integral vehicle body side structure frame 1 taken along the line AA' includes the inner panel of the rocker and the inner panel of the A-pillar. The integral vehicle body side structure frame 1 is coupled to the inner panel 70 of the A-pillar and the inner panel 60 of the rocker.

[0097] The inner panel 70 of the A-pillar includes a lower flange 71 and an upper flange 72. The integral body side structural frame (specifically, the A-pillar portion 5) is connected to the inner panel 70 of the A-pillar via the upper flange 72. As described above, the lower flange 71 of the A-pillar does not fully fit with the A-pillar portion 5 of the body side structural frame 1, i.e., there is a gap between the lower flange 71 and the body side structural frame 1. Such a gap may represent a weakness in structural performance in the event of a collision.

[0098] The inner panel 60 of the rocker includes a lower flange 61 and an upper flange 72. The body side structural frame is connected to the inner panel 60 of the rocker through the lower flange 61. Similar to the connection of the inner panel 70 of the A-pillar to the A-pillar portion 5, the inner panel 60 of the rocker does not fully mate with the rocker portion 3 of the body side structural frame 1. This gap can also be a structural weakness.

[0099] right Figure 1 and Figure 2 The blanks of the monocoque side structural frame are welded edge to edge and therefore have no overlapping areas.

[0100] Figure 3 An example of an integral body side structural frame 1 of a vehicle is shown. In this example, Figure 3 The vehicle body side structural frame 1 is a front frame. The vehicle body side structural frame has an integral structure in which a lower beam portion includes a rocker portion 3, an upper beam portion includes an A-pillar portion 5, a front beam portion includes a hinge pillar portion 4 connecting the rocker portion 3 to the A-pillar portion 5, and a rear beam portion includes a B-pillar portion 2 connecting the rocker portion 3 to the A-pillar portion 5. The B-pillar portion may include a U-shaped section having two lateral flanges.

[0101] Figure 3 The integral vehicle body side structural frame 1 is prepared from two blanks: a first blank 10 and a second blank 20, which are combined with each other to form a composite blank, and the composite blank is deformed to form the integral vehicle body side structural frame 1. The first blank 10 and the second blank partially overlap in the overlapping area 11, that is, only a part of the first blank overlaps a part of the second blank.

[0102] exist Figure 3In the example of the embodiment of the present invention, the first blank 10 and the second blank 20 are spot welded by the overlap area 11. In this specific example, the overlap area 11 is located at the lower part of the first blank 10. The upper part of the first blank 10 can be laser welded to the second blank 20 by the laser welding line 19. Laser welding the upper part of the first blank 10 to the second blank 20 can involve the step of removing the coating of the blank or using a powder or wire to resist the effect of the coating. Other methods of resisting the negative effects of the coating can be used for those joints without overlap, such as oscillating the laser beam applied to the welding zone or applying a magnetic field in the welding zone to mix the coating and base material of the blank.

[0103] In this example, one blank (first blank 10) may include at least a portion of the B-pillar portion 2, and another blank may include the remainder of the body side structural frame, for example, the second blank 20 may include at least a portion of the rocker portion 3, the hinge portion 4, and the A-pillar portion 5. The first blank, which generally corresponds to the B-pillar, may therefore have a generally elongated shape. Such a shape may help optimize the use of material in the coil to form the blank and minimize waste.

[0104] In this example, the overlap region 11 may be arranged substantially in the transition area between the rocker portion 3 and the B-pillar portion 2. This overlap region may be referred to as a formed B-pillar-rocker overlap region 11.

[0105] In further examples, one or more overlap regions may additionally or alternatively be disposed in other portions of the unibody side structural frame.

[0106] Figure 4 Schematically represents the Figure 3 FIG. 1 is a cross-sectional view of the integral body side structural frame 1 taken along line AA' of FIG. The body side structural frame 1 is coupled to the inner panel 70 of the A-pillar and the inner panel 60 of the rocker. The body side structural frame is connected to the inner panel 60 of the rocker by a lower flange 61. As the thickness of the body side structural frame increases in the overlap region 11, the overlap region 11 can provide the integral body side structural frame with sufficient rigidity to at least resist the negative structural effects of the inner panel 60 of the rocker and the rocker portion 3 that are not fully fitted to the body side structural frame 1.

[0107] Figure 5 is shown deformed to form Figure 3The composite blank 100 is prepared by bonding two blanks (bonding the first blank 10 to the second blank 20). The first blank 10 and the second blank 20 partially overlap in the overlap region 11. In this example, the upper portion of the first blank 10 is laser welded edge to edge to the second blank 20 via a weld line 19. Once the blanks are bonded to each other, the composite blank 100 is formed, and then the composite blank is deformed to form Figure 3 The integral body side structural frame shown in .

[0108] Deforming may include hot forming, i.e. heating the composite blank in an oven to a temperature possibly above the austenitizing temperature (specifically above Ac3). After heating in the oven, the blank may be transferred to a press where it is deformed to obtain the final shape of the body side structural frame. During forming and just after forming, quenching may be performed. In particular, quenching may include cooling above a critical cooling rate so that a martensitic microstructure is obtained. In some examples, quenching may be avoided in selected portions of the body side structural frame.

[0109] Fig. 6A Another example of an integral body side structural frame 1 of a vehicle is shown. Fig. 6A The integral body side structure frame 1 is a front frame and is prepared from four blanks. Each of the blanks may include at least a portion of one of the A-pillar portion 5, the B-pillar portion 2, the hinge pillar portion 4, and the rocker portion 3. For example, the first blank 10 may be bonded to the second blank 20 and the third blank 30, and the fourth blank 40 may be bonded to the second blank 20 and the third blank 30 on the opposite side. Fig. 6A , the first blank 10 may include at least a portion of the B-pillar portion 2 or the entire B-pillar portion 2, the second blank 20 may include at least a portion of the rocker portion 3, the third blank 30 may include at least a portion of the A-pillar portion and may include the entire A-pillar portion, and the fourth portion 40 may include at least a portion of the hinge pillar portion 4.

[0110] In these examples, the integral body side frame may include two or more overlapping regions. For example, one overlapping region 11 corresponds to or is disposed at a transition region between the rocker portion 3 and the B-pillar portion 2. The overlapping region may be referred to as a B-pillar-rocker overlapping region 11. The integral body side structural frame may further include an A-pillar-hinge pillar overlapping region 13 corresponding to or is disposed at a transition region between the A-pillar and the hinge pillar.

[0111] The blanks joined by the overlapping area can be spot welded. The other blanks (ie the joined blanks without overlapping area between them) can be welded to each other along the welding line 19.

[0112] The B-pillar-sill overlap region 11 may have a length (distance along the longitudinal axis of the sill) similar to the width of the B-pillar portion (i.e., from one lateral flange to the other lateral flange) and a height (distance along the longitudinal axis of the B-pillar) similar to the height of the sill portion 3 (i.e., from the lower flange to the upper flange of the sill portion). In other examples, the height of the B-pillar-sill overlap region 11 may be less than the height of the sill portion. The A-pillar-hinge overlap region 13 may have a length similar to the width of the hinge pillar portion.

[0113] In some examples, the area extending from the hinge pillar to the A-pillar may be subject to high loads in the event of a collision. By increasing the thickness of the third overlapping region, the stiffness of this region is increased.

[0114] Figure 6B Shows something like Fig. 6A Another example of an integral body side structural frame 1 of a vehicle of the example depicted in FIG. Figure 6B The vehicle body side structural frame 1 includes a first blank 10 having a B-pillar portion 2, and is joined to a second blank 20 in a B-pillar-sill overlap region 11, and is joined to a third blank 30 in an A-pillar-B-pillar overlap region 12. In the figure, the second blank 20 includes a rocker portion 3, and is also joined to a fourth blank 40 via a hinge-rocker overlap region 14. The fourth blank 40 (which may include a hinge portion 4) may also be joined to the third blank in an A-pillar-hinge overlap region 13. In these examples, the third blank 30 includes a portion of an A-pillar portion 5. Figure 6B In the embodiment, the integral body side structural frame 1 is thus formed from four blanks.

[0115] In other examples, the integral body side structural frame may be formed from additional blanks that may be joined between them or to any of the above blanks by overlapping areas or by edge-to-edge weld lines.

[0116] Figure 7 Shows something like Fig. 6A and Figure 6B Another example of an integral body side structural frame 1 of a vehicle of the example depicted in FIG. Figure 7 In the embodiment, the vehicle body side structural frame 1 includes a B-pillar-sill overlap region 11 (in which the first blank 10 and the second blank 20 partially overlap), and an A-pillar-B-pillar overlap region 12, in which the first blank 10 and the third blank 30 partially overlap.

[0117] exist Figure 7, the B-pillar-rocker overlap region 11 has a length corresponding to the width of the B-pillar portion 2 in its lower portion and a height corresponding to half the height of the rocker portion 3. According to this aspect, the first blank 10 does not completely cover the height of the rocker portion 3. Similarly, the A-pillar-B-pillar overlap region 12 can have a length corresponding to the width of the B-pillar portion 2 in its upper portion and a height corresponding to half the height of the A-pillar portion 5. In other examples, the shape of the overlap region can be adapted to the shape of the body side structural frame and / or the structural performance of the vehicle.

[0118] In these examples, the fourth blank 4 is welded to the third blank 3 and the second blank 5 along a welding line 19. Alternatively, according to any of the examples described herein, the joints may be made by partially overlapping the blanks.

[0119] In order to control deformation of the integral body side structural frame or to increase the energy absorbed by the body side structural frame in the event of a collision while at least maintaining the overall strength of the body side structural frame, the integral body side structural frame may include regions having different mechanical properties.

[0120] Figure 7 The integral vehicle body side structural frame 1 may have been deformed by hot forming and then quenched. Figure 7 The integral body side structural frame is made of four blanks of boron steel with aluminum-silicon coating. After press hardening, the body side structural frame has a main substantially martensitic microstructure with a tensile strength greater than 1400 MPa. However, the first blank 10 of the body side structural frame includes a region 25 with lower tensile strength. This region 25 with lower tensile strength has a microstructure different from the martensitic structure. Such a lower strength region 25 may contain ferrite and / or bainite and / or pearlite and / or tempered martensite and / or a mixture thereof. Accordingly, the tensile strength of the lower strength region may be lower than 1000 MPa. The ductility of this region is thus increased, and therefore the energy absorption may be increased, and the deformation of the body side structural frame may be more accurately controlled. The integral body side structural frame may thus have a region (i.e., a hard region) with a tensile strength greater than 1400 MPa and a region (i.e., a soft region) with a tensile strength less than 1000 MPa.

[0121] exist Figure 7, the lower strength region 25 is arranged on the lower portion of the first blank 10. The lower strength region 25 may be arranged just above the B-pillar-sill overlap region 11. According to this aspect, the B-pillar-sill overlap region 11 may correspond to the lowermost region of the B-pillar portion 2. As a result, the B-pillar-sill overlap region 11 (i.e., the region where the first blank and the second blank partially overlap) provides rigidity to the vehicle body side structural frame, and the region 25 having a lower strength helps control the deformation of the B-pillar portion in a manner that can reduce the intrusion of the portion during a collision.

[0122] Such regions 25 with lower strength can be formed by differential cooling of these regions of the composite blank when the composite blank is pressed in the press tool during the hot forming die quenching process used to form the body side structural frame. Alternatively, such regions can be produced by differential heating during hot forming, avoiding these regions from reaching temperatures above the austenitizing temperature. In another example, the lower strength can be achieved by partially heating some regions of the integral body side structural frame after press hardening to change the microstructure in these regions.

[0123] In yet another example, rather than changing the microstructure to transform mechanical properties (e.g., tensile strength and elongation), the region of lower strength may be formed of a material having different mechanical properties relative to the remainder of the body side structural frame. For example, the region of lower strength 25 may be formed of prepared, and the remaining part of the body side structural frame can be made of preparation.

[0124] In other examples, a plurality of blanks may have different thicknesses. In further examples, some of the blanks may be composed of parts having different thicknesses.

[0125] In any of the examples disclosed herein, the unitary body side structural frame may also include "patchwork," ie, localized reinforcements disposed on the composite blank.

[0126] It should be noted that these different strategies for improving the response of the integral body side structural frame in the event of a collision can be combined in the body side structural frame and even in at least one blank.

[0127] According to other examples, the integral body side structural frame may include one or more lower strength areas to provide a relatively stable structure according to the embodiment of the present invention. Figure 7 Any of the examples described can be used to improve the framework.

[0128] Although in the previous examples, the integral body side structural frame is bonded to the lower flange of the inner panel of the rocker and the upper flange of the inner panel of the A-pillar, the body side structural frame may alternatively be bonded to the outer panel of the rocker and / or the outer panel of the A-pillar. In some cases, the frame of the vehicle may include the outer panel of the rocker or A-pillar, rather than the inner panel (e.g., for manufacturing purposes), before bonding the body side structural frame. Figure 8A-8B An example of an integral body side structural frame coupled to an A-pillar panel and a rocker panel is shown.

[0129] exist Fig. 8A In the embodiment, the lower portion of the integral vehicle body side structural frame 1 is joined to the lower flange of the inner panel of the rocker 60. In this example, the second blank 20 is formed with Figure 4 A similar manner is provided to bond to the lower flange 61 of the inner panel of the rocker 60. The third blank 30 may be bonded to the upper flange 77 of the outer panel 75 of the A-pillar.

[0130] In contrast, Figure 8B In the embodiment, the second blank 20 is bonded to the lower flange 66 of the outer panel of the door sill 65, and the third blank 30 is bonded to the lower flange 66 of the outer panel of the door sill 65. Figure 4 The upper flange 72 of the inner panel of the A-pillar 70 is similarly bonded.

[0131] Fig. 9 Another example of the integral body side structural frame 1 of a vehicle is shown, wherein the integral body side structural frame is a rear frame. In this example, the lower beam portion may include a rocker portion 3, the front pillar portion may include a B-pillar portion 2, and the rear pillar portion and the upper beam portion may include a C-pillar portion 6 extending from the rocker portion 3 to the B-pillar portion 2.

[0132] The integral body side structural frame 1 includes one or more overlap regions. In the figure, the structural frame 1 includes a B-pillar-sill overlap region 11 and a C-pillar-B-pillar overlap region 16. The structural frame 1 of the figure includes three blanks: one blank 10 including a B-pillar portion 2, another blank 20 including a rocker portion 3, and the remaining blank 50 including a C-pillar portion 6. In this example, the blanks 10 and 50 partially overlap in the C-pillar-B-pillar overlap region 16, and the blanks 10 and 20 partially overlap in the B-pillar-sill overlap region 11. However, the blanks 20 and 50 are joined to each other edge to edge by a weld line 19.

[0133] In other examples, the structural frame 1 may include only one of the B-pillar-rocker overlap region 11 and the C-pillar-B-pillar overlap region 16 .

[0134] Alternatively or additionally, one of the overlapping regions may substantially correspond to a transition region between a C-pillar portion and a rocker portion, ie the structural frame may include a C-pillar-rocker overlapping region.

[0135] Fig.10 Another example of an integral body side structural frame 1 of a vehicle is shown, wherein the integral body side structural frame surrounds a single opening for a front door and a rear door of the vehicle. In this example, the lower beam portion may include a rocker portion 3, the front pillar portion may include a hinge pillar portion 4, the rear pillar portion may include a C-pillar portion 6, and the upper beam portion may include an A-pillar portion 5. The A-pillar portion 5 may extend from the hinge portion 4 to the C-pillar portion 6, and the C-pillar portion 6 may extend from the rocker portion 3 to the A-pillar portion 6.

[0136] In this figure, the integral body side structural frame 1 comprises an overlap region 17 arranged in the A-pillar section 2. The A-pillar section 2 can thus be formed by partially overlapping the blanks 31 and 32. The connection between the other blanks can be made by an edge-to-edge welding line 19.

[0137] In other examples, one or more overlapping regions may be arranged in other portions of the unibody side structural frame 1 .

[0138] In some examples, the structural frame 1 may include an A-pillar-hinge overlap region that generally corresponds to a transition area between the A-pillar portion and the hinge pillar portion.

[0139] Alternatively or additionally, one of the overlapping regions may substantially correspond to a transition region between the C-pillar portion and the rocker portion, ie the structural frame may include a C-pillar-rocker overlapping region.

[0140] Alternatively or additionally, one of the overlapping regions may substantially correspond to a transition zone between the hinge portion and the sill portion, ie the structural frame may comprise a hinge-sill overlapping region.

[0141] In these examples, the integral body side structural frame 1 does not include a B-pillar portion. However, the B-pillar may be formed separately and joined to the integral body side structural frame to form a "non-integral" body side structural frame.

[0142] In a further aspect, a method for manufacturing a body side structural frame prepared by a B-pillar coupled to an integral body side structural frame is provided. The method comprises: providing an integral body side structural frame without a B-pillar portion for enclosing both a front door opening and a rear door opening according to any of the examples disclosed herein, providing a B-pillar, and coupling the B-pillar to the integral front side structural frame. As a result, a "non-integral" body side structural frame can be manufactured.

[0143] Fig.11Another example of a vehicle's integral body side structural frame 1 similar to the integral body side structural frame including a B-pillar portion 2 is shown. In this example, the blank including the B-pillar portion is joined to other blanks before being deformed (e.g., thermoformed). The B-pillar portion 2 may be disposed between the hinge pillar 4 and the C-pillar portion 6, and may extend from the rocker portion 3 to the A-pillar portion 5.

[0144] In addition to Fig.10 In addition to the A-pillar overlap region 17 as in the above, the integral vehicle body side structure frame 1 may also additionally include a B-pillar-sill overlap region 11 and an A-pillar-B-pillar overlap region 12 .

[0145] The integral vehicle body side structural frame 1 may include Fig.10 Any combination of one or more of the described overlapping regions.

[0146] In yet another aspect, a method for manufacturing a body side structural frame prepared from two integral body side structural frames is provided. The method includes: providing an integral front body side structural frame according to any of the examples disclosed herein, providing an integral rear body side structural frame according to any of the examples disclosed herein, and combining the front body side structural frame and the rear body side structural frame along the B-pillar portion to form the body side structural frame. Thus, the resulting structural frame is a "non-integral" body side structural frame.

[0147] For reasons of completeness, various aspects of the disclosure are listed in the following numbered clauses:

[0148] Clause 1. A method for manufacturing an integral body side structural frame of a vehicle, the method comprising:

[0149] Providing a plurality of blanks;

[0150] bonding the blanks to each other to form a composite blank, wherein bonding the blanks includes forming one or more overlapping regions formed by partially overlapping two blanks;

[0151] deforming the composite blank to form the integral body side structural frame;

[0152] The integral vehicle body side structural frame includes a lower beam portion and an upper beam portion, a front pillar portion connecting the lower beam portion to the upper beam portion, and a rear pillar portion connecting the lower beam portion to the upper beam portion.

[0153] Clause 2. A method for manufacturing an integral vehicle body side structural frame according to clause 1, wherein joining the blanks to each other comprises welding the blanks to each other in the one or more overlapping regions; and specifically comprises spot welding the blanks at least one in the overlapping region.

[0154] Clause 3. A method for manufacturing a unitary vehicle body side structural frame according to any one of clauses 1-2, wherein at least one of the overlapping regions substantially corresponds to a transition zone between a beam portion and a pillar portion.

[0155] Clause 4. The method for manufacturing a unitary vehicle body side structural frame according to any one of clauses 1 to 3, wherein at least one of the overlapping regions is arranged in a beam portion and / or a pillar portion.

[0156] Clause 5. The method for manufacturing a unitary body side structural frame according to any one of clauses 1-4, wherein deforming the composite blank to form the unitary body side structural frame comprises thermoforming the composite blank.

[0157] Clause 6. The method for manufacturing a unitary vehicle body side structural frame according to any one of clauses 1-5, wherein the plurality of blanks comprise different materials and / or thicknesses.

[0158] Clause 7. The method for manufacturing a unitary body side structural frame according to any one of clauses 1 to 6, wherein the unitary body side structural frame comprises a portion of an outer frame.

[0159] Clause 8. The method for manufacturing a vehicle body side structural frame according to Clause 7, wherein the vehicle body side structural frame is an outer frame.

[0160] Clause 9. The method for manufacturing a unitary body side structural frame according to any one of clauses 1 to 7, wherein the unitary body side structural frame comprises a portion of an inner frame.

[0161] Clause 10. The method for manufacturing a vehicle body side structure frame according to Clause 9, wherein the vehicle body side structure frame is an inner frame.

[0162] Clause 11. The method for manufacturing an integral vehicle body side structural frame according to any one of Clauses 1 to 6, wherein the integral vehicle body side structural frame comprises a portion of an outer frame and a portion of an inner frame.

[0163] Clause 12. A method for manufacturing a unitary vehicle body side structural frame according to any one of clauses 1 to 11, wherein the unitary vehicle body side structural frame is a front frame; and wherein

[0164] The lower beam portion includes a threshold portion;

[0165] The upper beam portion includes an A-pillar portion;

[0166] The front pillar portion includes a hinge pillar portion; and

[0167] The rear pillar portion includes a B-pillar portion.

[0168] Clause 13. The method for manufacturing a unitary vehicle body side structural frame according to Clause 12, wherein one of the overlapping regions substantially corresponds to a transition region between the rocker portion and the B-pillar portion.

[0169] Clause 14. The method for manufacturing a unitary vehicle body side structural frame according to any one of clauses 12-13, wherein one of the overlapping regions substantially corresponds to a transition region between the B-pillar portion and the A-pillar portion.

[0170] Clause 15. The method for manufacturing a unitary vehicle body side structural frame according to any one of clauses 12-14, wherein one of the overlapping regions substantially corresponds to a transition region between the A-pillar portion and the hinge pillar portion.

[0171] Clause 16. The method for manufacturing a unitary vehicle body side structural frame according to any one of clauses 12-15, wherein one of the overlapping regions substantially corresponds to a transition region between the rocker portion and the hinge pillar portion.

[0172] Clause 17. The method for manufacturing a unitary vehicle body side structural frame according to any one of clauses 12-16, wherein one of the overlapping regions is arranged in the A-pillar portion.

[0173] Clause 18. A method for manufacturing a unitary vehicle body side structural frame according to any one of clauses 1 to 11, wherein the unitary vehicle body side structural frame is a rear frame; and wherein

[0174] The lower beam portion includes a threshold portion;

[0175] The front pillar portion includes a B-pillar portion;

[0176] The upper beam portion and the rear pillar portion include a C-pillar portion extending from the rocker portion to the B-pillar portion.

[0177] Clause 19. The method for manufacturing a unitary vehicle body side structural frame according to Clause 18, wherein one of the overlapping regions substantially corresponds to a transition region between the rocker portion and the B-pillar portion.

[0178] Clause 20. The method for manufacturing a unitary vehicle body side structural frame according to any one of clauses 18-19, wherein one of the overlapping regions substantially corresponds to a transition region between the B-pillar and the C-pillar portions.

[0179] Clause 21. The method for manufacturing a unitary vehicle body side structural frame according to any one of clauses 18-20, wherein one of the overlapping regions substantially corresponds to a transition region between the C-pillar portion and the rocker portion.

[0180] Clause 22. A method for manufacturing a monolithic vehicle body side structural frame according to any one of clauses 1 to 11, wherein

[0181] The lower beam portion includes a threshold portion;

[0182] The front pillar portion includes a hinge pillar portion;

[0183] The rear pillar portion includes a C-pillar portion;

[0184] The upper beam portion includes an A-pillar portion;

[0185] The A-pillar portion extends from the hinge pillar portion to the C-pillar portion, and the C-pillar portion extends from the rocker portion to the A-pillar portion.

[0186] Clause 23. The method for manufacturing a unitary vehicle body side structural frame according to Clause 22, wherein one of the overlapping regions substantially corresponds to a transition region between the A-pillar portion and the hinge pillar portion.

[0187] Clause 24. The method for manufacturing a unitary vehicle body side structural frame according to any one of clauses 22-23, wherein one of the overlapping regions substantially corresponds to a transition area between the rocker and the C-pillar portion.

[0188] Clause 25. The method for manufacturing a unitary vehicle body side structural frame according to any one of clauses 22-24, wherein one of the overlap regions substantially corresponds to a transition region between the rocker and the hinge pillar portion.

[0189] Clause 26. The method for manufacturing a unitary vehicle body side structural frame according to any one of clauses 22-25, wherein one of the overlapping regions substantially corresponds to a transition region between the A-pillar portion and the C-pillar portion.

[0190] Clause 27. The method for manufacturing a unitary vehicle body side structural frame according to any one of clauses 22-26, wherein one of the overlapping regions is arranged in the A-pillar portion.

[0191] Clause 28. A method for manufacturing an integral vehicle body side structural frame according to any one of Clauses 22-27, wherein the integral vehicle body side structural frame further includes a B-pillar portion, the B-pillar portion being arranged between the hinge pillar portion and the C-pillar portion and extending from the rocker portion to the A-pillar portion.

[0192] Clause 29. The method for manufacturing a unitary vehicle body side structural frame according to Clause 27, wherein one of the overlapping regions substantially corresponds to a transition region between the rocker portion and the B-pillar portion.

[0193] Clause 30. The method for manufacturing a unitary vehicle body side structural frame according to any one of clauses 28-29, wherein one of the overlapping regions substantially corresponds to a transition region between the B-pillar portion and the A-pillar portion.

[0194] Clause 31. An integral body side structural frame as obtainable by a method according to any one of clauses 1-30.

[0195] Clause 32. The integral body side structural frame of Clause 31, wherein the integral body side structural frame comprises regions having different tensile strengths, and optionally wherein the regions having different tensile strengths have different microstructures.

[0196] Clause 33. A method for manufacturing a vehicle body side structural frame, the method comprising:

[0197] Providing an integral front body side structural frame according to any one of clauses 12 to 17;

[0198] Providing an integral rear body side structural frame according to any one of clauses 18 to 21;

[0199] The front body side structural frame and the rear body side structural frame are combined along the B-pillar portion to form a body side structural frame.

[0200] Clause 34. A method for manufacturing a vehicle body side structural frame, the method comprising:

[0201] Providing a one-piece vehicle body side structural frame according to any one of clauses 22 to 27;

[0202] Provide B-pillar;

[0203] The B-pillar is coupled to the unibody side structural frame.

[0204] Clause 35. A method for manufacturing a vehicle body side structural frame, the method comprising:

[0205] Providing an external integral body side structural frame according to clause 8;

[0206] Providing an inner integral body side structural frame according to clause 10;

[0207] The outer frame and the inner frame are coupled to each other to form a vehicle body side structural frame.

[0208] Although only some examples are disclosed herein, other alternative examples, modifications, uses and / or equivalents are possible. In addition, all possible combinations of the examples are also covered. Therefore, the scope of the present disclosure should not be limited to specific examples, but should only be determined by the appended claims that are properly interpreted.

Claims

1. A method for manufacturing an integral body side structural frame of a vehicle, the method comprising: A plurality of blanks (10; 20; 30; 40； 50)； bonding the blanks to each other to form a composite blank, wherein bonding the blanks includes forming one or more overlapping regions formed by partially overlapping two blanks; deforming the composite blank to form the integral body side structural frame; The integral vehicle body side structural frame (1) comprises: A lower beam portion, the lower beam portion including a threshold portion (3); Upper beam part; a front pillar portion connecting the lower beam portion to the upper beam portion; and connecting the lower beam portion to the rear pillar portion of the upper beam portion, The integral vehicle body side structural frame (1) comprises a B-pillar portion (2), wherein one of the overlapping regions (11) is included in the rocker portion (3) and corresponds to a transition region between the rocker portion (3) and the B-pillar portion (2), The integral body side structural frame (1) is configured to be attached to a lower flange (61, 66) of an inner panel (60) or an outer panel (65) of a rocker, so that a gap is provided between a transition between the rocker portion (3) and the B-pillar portion (2) and an upper flange (62, 67) of the inner panel (60) or the outer panel (65). 2 . The method for manufacturing a vehicle body side structural frame according to claim 1 , wherein joining the blanks to each other comprises welding the blanks to each other in the one or more overlapping regions. 3 .

3. The method for manufacturing a monocoque vehicle body side structural frame according to claim 1, wherein The integral body side structural frame is a front frame; and wherein The upper beam portion includes an A-pillar portion (5); The front pillar portion includes a hinge pillar portion (4); and The rear pillar portion includes the B-pillar portion (2).

4. The method for manufacturing a monolithic vehicle body side structural frame according to claim 3, wherein one of the overlapping regions substantially corresponds to a transition area between the B-pillar portion (2) and the A-pillar portion (5).

5. The method for manufacturing a one-piece vehicle body side structural frame according to claim 3, wherein one of the overlapping areas substantially corresponds to a transition area between the A-pillar portion (5) and the hinge pillar portion (4).

6. The method for manufacturing a monocoque vehicle body side structural frame according to claim 3, wherein one of the overlapping regions substantially corresponds to a transition area between the rocker portion (3) and the hinge pillar portion (4). 7 . The method for manufacturing a vehicle body side structural frame according to claim 1 , wherein deforming the composite blank to form the vehicle body side structural frame comprises thermoforming the composite blank. 8 . The method for manufacturing a vehicle body side structural frame according to claim 1 , wherein the plurality of blanks comprise different materials and / or different thicknesses.

9. The method for manufacturing a monocoque vehicle body side structural frame according to claim 1, wherein: The integral vehicle body side structural frame (1) is a rear frame, and The front pillar portion includes the B-pillar portion (2), and The upper beam portion and the rear pillar portion include a C-pillar portion (6) extending from the rocker portion (3) to the B-pillar portion.

10. The method for manufacturing a monocoque vehicle body side structural frame according to claim 1, wherein: The front pillar portion includes a hinge pillar portion (4), The rear pillar portion includes a C-pillar portion (6), The upper beam portion includes an A-pillar portion (5), and The A-pillar portion (5) extends from the hinge pillar portion (4) to the C-pillar portion (6), and the C-pillar portion (6) extends from the rocker portion (3) to the A-pillar portion (4).

11. The method for manufacturing an integral vehicle body side structural frame according to claim 1, wherein the overlapping area (11) corresponding to the transition zone between the rocker portion (3) and the B-pillar portion (2) has a length between 20 mm and 600 mm and a height between 20 mm and 600 mm.

12. The method for manufacturing an integral vehicle body side structural frame according to claim 1, wherein the overlapping area (11) corresponding to the transition zone between the rocker portion (3) and the B-pillar portion (2) has a length between 100 mm and 500 mm and a height between 100 mm and 500 mm.

13. A method for manufacturing an integral body side structural frame of a vehicle, the method comprising: A plurality of blanks (10; 20; 30; 40； 50)； bonding the blanks to each other to form a composite blank, wherein bonding the blanks includes forming one or more overlapping regions formed by partially overlapping two blanks; deforming the composite blank to form the integral body side structural frame; The integral vehicle body side structural frame (1) comprises: A lower beam portion, the lower beam portion including a threshold portion (3); An upper beam portion, the upper beam portion including an A-pillar portion (5); a front pillar portion connecting the lower beam portion to the upper beam portion; and connecting the lower beam portion to the rear pillar portion of the upper beam portion, The integral vehicle body side structural frame (1) comprises a B-pillar portion (2), wherein one of the overlapping regions (12) is included in the A-pillar portion (5) and corresponds to a transition zone between the A-pillar portion (5) and the B-pillar portion (2), The integral vehicle body side structural frame (1) is configured to be attached to an upper flange (72, 74) of an inner panel (70) or an outer panel (75) of an A-pillar, so that a gap is provided between the A-pillar with the A-pillar portion (5) and a lower flange (71, 76) of the inner panel (70) or the outer panel (75). 14 . The method for manufacturing a vehicle body side structural frame according to claim 13 , wherein joining the blanks to each other comprises welding the blanks to each other in the one or more overlapping regions.

15. The method for manufacturing a monocoque vehicle body side structural frame according to claim 13, wherein The integral body side structural frame is a front frame; and wherein The front pillar portion includes a hinge pillar portion (4); and The rear pillar portion includes the B-pillar portion (2).

16. The method for manufacturing a vehicle body side structural frame according to claim 15, wherein one of the overlapping regions substantially corresponds to a transition area between the B-pillar portion (2) and the rocker portion (3).

17. The method for manufacturing a one-piece vehicle body side structural frame according to claim 16, wherein one of the overlapping regions substantially corresponds to a transition area between the A-pillar portion (5) and the hinge pillar portion (4).

18. The method for manufacturing a single-body vehicle body side structural frame according to claim 16, wherein one of the overlapping regions substantially corresponds to a transition area between the rocker portion (3) and the hinge pillar portion (4).

19. A method for manufacturing an integral vehicle body side structural frame according to claim 13, wherein the integral vehicle body side structural frame (1) is configured to be attached to an upper flange (72) of an inner panel (70) of the A-pillar, so that a gap is provided between a transition between the A-pillar portion (5) and the B-pillar portion (2) and a lower flange (71) of the inner panel (70).

20. A method for manufacturing an integral vehicle body side structural frame according to claim 13, wherein the integral vehicle body side structural frame (1) is configured to be attached to an upper flange (74) of an outer panel (75) of the A-pillar, so that a gap is provided between a transition between the A-pillar portion (5) and the B-pillar portion (2) and a lower flange (76) of the outer panel (75).

21. The method for manufacturing a vehicle body side structural frame according to claim 13, wherein deforming the composite blank to form the vehicle body side structural frame comprises thermoforming the composite blank.

22. The method for manufacturing a vehicle body side structural frame according to claim 13, wherein the plurality of blanks comprise different materials and / or different thicknesses.

23. The method for manufacturing a monocoque vehicle body side structural frame according to claim 13, wherein: The front pillar portion includes a hinge pillar portion (4), The rear pillar portion includes a C-pillar portion (6), The upper beam portion includes the A-pillar portion (5), and The A-pillar portion (5) extends from the hinge pillar portion (4) to the C-pillar portion (6), and the C-pillar portion (6) extends from the rocker portion (3) to the A-pillar portion (4).

24. The method for manufacturing a monocoque vehicle body side structural frame according to claim 13, wherein the overlap region (12) has a length between 20 mm and 600 mm, and a height between 20 mm and 600 mm.

25. The method for manufacturing a vehicle body side structural frame according to claim 13, wherein the overlap region (12) has a length between 100 mm and 500 mm, and a height between 100 mm and 500 mm.

26. The method for manufacturing a vehicle body side structural frame according to claim 23, wherein one of the overlapping regions substantially corresponds to a transition between the B-pillar portion (2) and the rocker portion (3).

27. The method for manufacturing a unitary vehicle body side structural frame according to claim 26, wherein the overlap region substantially corresponding to the transition between the B-pillar portion (2) and the rocker portion (3) is included in the B-pillar portion (2).

28. A method for manufacturing an integral body side structural frame of a vehicle, the method comprising: A plurality of blanks (10; 20; 30; 40； 50)； bonding the blanks to each other to form a composite blank, wherein bonding the blanks includes forming a plurality of overlapping regions formed by partially overlapping two adjacent blanks; deforming the composite blank to form the integral body side structural frame; The integral vehicle body side structural frame (1) comprises: A lower beam portion, the lower beam portion including a threshold portion (3); Upper beam part; a front pillar portion connecting the lower beam portion to the upper beam portion; and connecting the lower beam portion to a rear pillar portion of the upper beam portion, and wherein Each blank of the plurality of blanks is joined to two adjacent blanks by overlapping areas.

29. The method for manufacturing a one-piece vehicle body side structural frame according to claim 28, wherein The integral body side structural frame is a front frame; and wherein The upper beam portion includes an A-pillar portion (5); The front pillar portion includes a hinge pillar portion (4); and The rear pillar portion includes the B-pillar portion (2).

30. The method for manufacturing an integral vehicle body side structural frame according to claim 29, wherein one of the overlapping areas (11) is included in the rocker portion (3) and corresponds to a transition between the rocker portion (3) and the B-pillar portion (2).

31. The method for manufacturing a unitary vehicle body side structural frame according to claim 30, wherein one of the overlapping regions substantially corresponds to a transition between the B-pillar portion (2) and the A-pillar portion (5).

32. The method for manufacturing a unitary vehicle body side structural frame according to claim 31, wherein one of the overlapping regions substantially corresponds to a transition between the A-pillar portion (5) and the hinge pillar portion (4).

33. The method for manufacturing a unitary vehicle body side structural frame according to claim 32, wherein one of the overlapping regions substantially corresponds to a transition between the rocker portion (3) and the hinge pillar portion (4).

34. The method for manufacturing a monocoque vehicle body side structural frame according to claim 28, wherein: The integral vehicle body side structural frame (1) is a rear frame, and The front pillar portion includes the B-pillar portion (2), and The upper beam portion and the rear pillar portion include a C-pillar portion (6) extending from the rocker portion (3) to the B-pillar portion.

35. The method for manufacturing a monocoque vehicle body side structural frame according to claim 28, wherein: The front pillar portion includes a hinge pillar portion (4), The rear pillar portion includes a C-pillar portion (6), The upper beam portion includes an A-pillar portion (5), and The A-pillar portion (5) extends from the hinge pillar portion (4) to the C-pillar portion (6), and the C-pillar portion (6) extends from the rocker portion (3) to the A-pillar portion (4).

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