Vehicle structure

Abstract

A vehicle structure (100, 300) includes a portion (102) including first and second members (108, 112) that form an enclosed space (120). The portion (102) includes one or more tubular reinforcing members (122a, 122b) positioned within the enclosed space (120). The tubular reinforcing members (122a, 122b) are corrugated. The tubular reinforcing members (122a, 122b) include two or more member sections (130a, 130b) arranged side by side in a longitudinal direction (106). One (130a) of the member sections (130a, 130b) bulges outward in a first direction (132) and a second direction (134) opposite the first direction (132) and bulges inward in a third direction (136) transverse to the first and second directions (132, 134), while another one (130b) of the member sections (130a, 130b) adjacent to said one (130a) of the member sections (130a, 130b) bulges inward in the first and second directions (132, 134) and bulges outward in the third direction (136).

Description

[Technical Field]

[0001] An aspect of the present invention relates to a vehicle structure including a portion having a longitudinally extending portion, the portion including a first member having a longitudinally extending portion and a second member having a longitudinally extending portion, the first and second members being attached to one another such that the first and second members form an enclosed space. [Background technology]

[0002] In the design of a frame section of a motor vehicle, there is a trade-off between weight and strength. For example, an advantageous way to obtain a good trade-off is to manufacture the frame section from one or more metal or metal alloy plates formed into the required shape, e.g., a hat-shaped profile.

[0003] Generally, frame portions of a motor vehicle are formed to have a certain rigidity because they may be subjected to various external impacts. At the same time, some frame portions must be able to deform to absorb the impact when overloaded, for example, due to a collision with an external object, such as another vehicle or a stationary object, such as a tree. An example of a vehicle frame portion that must be rigid yet able to deform to absorb the impact is a vehicle side sill structure, or a bumper or bumper beam. Summary of the Invention [Means for solving the problem]

[0004] The inventors of the present invention have identified drawbacks with conventional vehicle frame sections, such as those described above. For example, some conventional solutions do not provide sufficient deformation to absorb impacts while being sufficiently rigid. For example, some conventional vehicle frame sections are complex to manufacture.

[0005] It is an object of the present invention to provide a solution that alleviates or overcomes the drawbacks and problems of prior solutions.

[0006] These and further objects are solved by the subject matter of the independent claims. Further advantageous embodiments of the invention can be found in the dependent claims.

[0007] According to a first aspect of the present invention, the above and other objects are achieved by a vehicle structure comprising a part having a longitudinally extending portion, the part comprising: a first member having a longitudinally extending portion extending in a longitudinal direction; a second member having a longitudinally extending portion extending in the longitudinal direction; Equipped with The first member is configured to face an interior side of the vehicle; The second member is configured to face an exterior of the vehicle; the first and second members are attached to each other such that the first and second members form a closed space; the section comprising one or more tubular reinforcing members positioned within the enclosed space; The tubular reinforcing member has a longitudinally extending portion extending in a longitudinal direction, the tubular reinforcing member is corrugated and includes a corrugated portion; the tubular reinforcing member comprises two or more member sections arranged longitudinally side by side; One of the member sections bulges outward in a first direction and a second direction opposite the first direction and bulges inward in a third direction transverse to the first and second directions, while another of the member sections adjacent to said one of the member sections bulges inward in the first and second directions and bulges outward in the third direction.

[0008] Due to the innovative configuration of the tubular reinforcing member, the corrugated tubular reinforcing member may be described as having or forming two or more corrugations that are not coincident with each other but are offset relative to each other in the longitudinal direction or in the direction of the longitudinal extension of the tubular reinforcing member. The two or more corrugations may be described as providing a zigzag (or alternating) structure or appearance to the corrugated tubular reinforcing member and / or adjacent member sections. That is, when one longitudinal side of the tubular reinforcing member bulges outward in any cross-section along the longitudinal extension of the tubular reinforcing member, another longitudinal side of the tubular reinforcing member bulges inward in the same cross-section, and vice versa in subsequent longitudinal cross-sections.

[0009] An advantage of the vehicle structure according to the first aspect of the present invention is that it provides advantageous deformation of the vehicle structure to absorb an impact while maintaining or improving the stiffness and reinforcement of the vehicle structure to prevent penetration during a collision, for example a side or lateral collision. An advantage of the vehicle structure according to the first aspect of the present invention is that the motion and load distribution of the vehicle structure during a collision can be efficiently controlled, i.e. the way in which the vehicle structure deforms and / or collapses during a collision can be efficiently controlled. An advantage of the vehicle structure according to the first aspect of the present invention is that it improves energy absorption by the vehicle structure during a collision, for example the vehicle structure provides high energy absorption during a collision while being sufficiently stiff and reinforced to prevent penetration of external objects into the vehicle interior during a collision.

[0010] An advantage of the vehicle structure according to the first aspect of the present invention is that the process of manufacturing the tubular reinforcing members is easier with respect to conventional solutions. An advantage of the vehicle structure according to the first aspect of the present invention is that the process of assembling the vehicle structure is easier with respect to conventional solutions, for example, including tubular reinforcing members with a circular cross section. For example, the tubular reinforcing members of the vehicle structure according to the first aspect are less bulky and therefore provide a vehicle structure that is less bulky compared to conventional tubular reinforcing members with a circular cross section and conventional solutions including such conventional tubular reinforcing members, yet has sufficient strength and sufficient stopping power against penetration of external objects into the vehicle interior in the event of a collision.

[0011] An advantage of the vehicle structure according to the first aspect of the invention is that the weight and cost of the vehicle structure may be reduced whilst maintaining or improving the stiffness and reinforcement of the vehicle structure. An advantage of the vehicle structure according to the first aspect of the invention is that the performance of the vehicle structure in a crash is improved, for example because the vehicle structure may be deformed in a more controlled and more predictable manner, thereby providing an improved vehicle structure.

[0012] The vehicle structure may be for a motor vehicle with a combustion engine, an electric vehicle, or a hybrid vehicle having one or more electric batteries. For example, the vehicle may be a car or a truck. The vehicle structure may be configured to protect the electric battery of the electric vehicle or hybrid vehicle, for example, during a collision. The vehicle structure may be located on one or more sides of an electric battery located within the vehicle. The vehicle structure is effective in protecting the electric battery, the driver, and / or one or more occupants of the vehicle during a collision.

[0013] The vehicle structure is efficient as protection against pole impacts or crashes. The vehicle structure is efficient in preventing the penetration of a pole into the interior of the vehicle during a pole impact. Thus, the vehicle structure provides efficient penetration resistance, i.e. the vehicle structure is efficient in preventing the penetration of external objects into the interior of the vehicle during a collision. This is an important aspect with regard to electric battery protection.

[0014] The above-mentioned "enclosed space" also includes a space that is substantially or essentially closed, for example, there may be one or more small openings in the edges of the walls and / or portions of the vehicle structure that form the enclosed space.

[0015] According to an advantageous embodiment of the vehicle structure according to the first aspect, the tubular reinforcing element comprises one or more flat areas extending along the entire longitudinal extension of the tubular reinforcing element. An advantage of this embodiment is that the process of manufacturing the tubular reinforcing element is further simplified. An advantage of this embodiment is that the process of assembling the vehicle structure is further simplified, e.g., with respect to conventional solutions including tubular reinforcing elements with a circular cross section. For example, the flat areas can be used for efficient attachment of the tubular reinforcing element to one of the first and second elements. An advantage of this embodiment is that the tubular reinforcing element is further reduced in volume, thereby providing a vehicle structure that is further reduced in volume yet still has sufficient strength and sufficient blocking power against penetration of external objects into the vehicle interior during a collision. An advantage of this embodiment is that a further improved vehicle structure is provided.

[0016] According to a further advantageous embodiment of the vehicle structure according to the first aspect, one of the member sections bulges outward and inward in the first and second directions and inward in a third direction, while another of the member sections adjacent to said one of the member sections bulges inward and outward in the first and second directions and outward in the third direction. An advantage of this embodiment is that the process of manufacturing the tubular reinforcing member is further facilitated, in particular because the tubular reinforcing member can be simply placed in a die when forming it. An advantage of this embodiment is that the performance of the vehicle structure in a crash can be more efficiently adjusted, so that the vehicle structure can be deformed in a more controlled and more predictable manner. An advantage of this embodiment is that a further improved vehicle structure is provided.

[0017] According to another advantageous embodiment of the vehicle structure according to the first aspect, one of the member sections bulges outward in the first and second directions and inward in a third direction and a fourth direction opposite the third direction, while another of the member sections adjacent to said one of the member sections bulges inward in the first and second directions and outward in the third and fourth directions. An advantage of this embodiment is that the performance of the vehicle structure in a crash can be adjusted more efficiently, so that the vehicle structure can be deformed in a more controlled and more predictable manner. An advantage of this embodiment is that the performance of the vehicle structure in a crash is further improved. An advantage of this embodiment is that a further improved vehicle structure is provided.

[0018] According to yet another advantageous embodiment of the vehicle structure according to the first aspect, the corrugated portion of the tubular reinforcing member comprises an annular ridge, and said one of the outwardly and inwardly bulging member sections and said other one of the member sections together have the same annular ridge of one of the annular ridges. An advantage of this embodiment is that deformation of the vehicle structure to absorb impact is further improved while maintaining or improving the stiffness and reinforcement of the vehicle structure. An advantage of this embodiment is that performance of the vehicle structure in a crash is further improved. An advantage of this embodiment is that a further improved vehicle structure is provided.

[0019] According to yet another advantageous embodiment of the vehicle structure according to the first aspect, the annular ridge extends at least partially transversely in the longitudinal direction. An advantage of this embodiment is that the deformation of the vehicle structure to absorb impact is further improved while maintaining or improving the stiffness and reinforcement of the vehicle structure. An advantage of this embodiment is that the performance of the vehicle structure in a crash is further improved. An advantage of this embodiment is that a further improved vehicle structure is provided.

[0020] According to an advantageous embodiment of the vehicle structure according to the first aspect, the corrugated portion of the tubular reinforcing member comprises an annular groove, and said one of the outwardly and inwardly bulging member sections and said other one of the member sections together have the same annular groove of one of the annular grooves. An advantage of this embodiment is that deformation of the vehicle structure to absorb impact is further improved while maintaining or improving the stiffness and reinforcement of the vehicle structure. An advantage of this embodiment is that performance of the vehicle structure in a crash is further improved. An advantage of this embodiment is that a further improved vehicle structure is provided.

[0021] According to a further advantageous embodiment of the vehicle structure according to the first aspect, the annular groove extends at least partially transversely in the longitudinal direction. An advantage of this embodiment is that the deformation of the vehicle structure to absorb impact is further improved while maintaining or improving the stiffness and reinforcement of the vehicle structure. An advantage of this embodiment is that the performance of the vehicle structure in a crash is further improved. An advantage of this embodiment is that a further improved vehicle structure is provided.

[0022] According to another advantageous embodiment of the vehicle structure according to the first aspect, the annular ridge and the annular groove form one or more corrugations extending longitudinally along the longitudinal extension of the tubular reinforcing member. An advantage of this embodiment is that deformation of the vehicle structure to absorb impact is further improved while maintaining or improving the stiffness and reinforcement of the vehicle structure. An advantage of this embodiment is that performance of the vehicle structure in a crash is further improved. An advantage of this embodiment is that a further improved vehicle structure is provided.

[0023] According to yet another advantageous embodiment of the vehicle structure according to the first aspect, the annular ridge and the annular groove form a tubular reinforcing member. An advantage of this embodiment is that the deformation of the vehicle structure to absorb an impact is further improved, while maintaining or improving the stiffness and reinforcement of the vehicle structure. An advantage of this embodiment is that the performance of the vehicle structure in a crash is further improved. An advantage of this embodiment is that a further improved vehicle structure is provided.

[0024] According to yet another advantageous embodiment of the vehicle structure according to the first aspect, one of the member sections bulges outward and inward in the first and second directions and inward in the third and fourth directions, while another of the member sections adjacent to said one of the member sections bulges inward and outward in the first and second directions and outward in the third and fourth directions. An advantage of this embodiment is that the process of manufacturing the tubular reinforcing member is further simplified. An advantage of this embodiment is that the performance of the vehicle structure in a crash can be more efficiently tuned, so that the vehicle structure can be deformed in a more controlled and more predictable manner. An advantage of this embodiment is that a further improved vehicle structure is provided.

[0025] According to an advantageous embodiment of the vehicle structure according to the first aspect, the tubular reinforcing member comprises one or more flat areas for attachment of the tubular reinforcing member to one or more of the first and second members. An advantage of this embodiment is that the tubular reinforcing member can be simply attached to one or more of the first and second members at the flat areas, for example without the use of additional brackets, further facilitating the process of assembling the vehicle structure. An advantage of this embodiment is that a further improved vehicle structure is provided.

[0026] According to a further advantageous embodiment of the vehicle structure according to the first aspect, the member sections form one or more corrugations extending longitudinally along the longitudinal extension of the tubular reinforcing member. An advantage of this embodiment is that deformation of the vehicle structure to absorb impact is further improved while maintaining or improving the stiffness and stiffness of the vehicle structure. An advantage of this embodiment is that performance of the vehicle structure in a crash is further improved. An advantage of this embodiment is that a further improved vehicle structure is provided.

[0027] According to another advantageous embodiment of the vehicle structure according to the first aspect, the member sections form tubular reinforcing members. An advantage of this embodiment is that the deformation of the vehicle structure to absorb impact is further improved while maintaining or improving the stiffness and reinforcement of the vehicle structure. An advantage of this embodiment is that the performance of the vehicle structure in a crash is further improved. An advantage of this embodiment is that a further improved vehicle structure is provided.

[0028] According to yet another advantageous embodiment of the vehicle structure according to the first aspect, the tubular reinforcing member forms one or more welding openings for attaching the tubular reinforcing member to one or more of the first and second members. An advantage of this embodiment is that the process of assembling the vehicle structure is further facilitated. An advantage of this embodiment is that a further improved vehicle structure is provided.

[0029] According to yet another advantageous embodiment of the vehicle structure according to the first aspect, the tubular reinforcing element is hydroformed, hot gas formed, extruded or formed from one or more plates, which is an efficient way of manufacturing the tubular reinforcing element.

[0030] According to an advantageous embodiment of the vehicle structure according to the first aspect, the tubular reinforcing member is made of a material comprising or consisting of a metal or a metal alloy, which is an efficient way of manufacturing a strong tubular reinforcing member.

[0031] According to a further advantageous embodiment of the vehicle structure according to the first aspect, one or more of the first and second members are formed from a plate, which is an efficient way of manufacturing the first and second members.

[0032] According to an advantageous embodiment of the vehicle structure according to the first aspect, one or more of the first and second members are formed by hot pressing from one or more plates or by cold working from one or more plates, which is an efficient way of manufacturing the first and second members.

[0033] According to another advantageous embodiment of the vehicle structure according to the first aspect, one or more of the first and second members are made of a material comprising or consisting of a metal or a metal alloy, which is an efficient way of producing strong first and second members.

[0034] According to yet another advantageous embodiment of the vehicle structure according to the first aspect, one or more of the first and second members comprises: Hat-shaped profile, and ·U-shaped outline The present invention is provided with one of the following groups: This is an efficient way to manufacture the first and second members and provide an enclosed space.

[0035] According to yet another advantageous embodiment of the vehicle structure according to the first aspect, the vehicle structure is a vehicle side structure and the portion is a side portion. The vehicle structure is suitable for application as a vehicle side structure of a vehicle, thereby improving the performance of the vehicle side structure in a side or lateral collision. Thus, an improved vehicle side structure is provided. However, in alternative embodiments, the vehicle structure may be applied and mounted elsewhere on the vehicle, for example at the front of the vehicle, where it may become part of the bumper, at the rear of the vehicle, or elsewhere within the vehicle.

[0036] According to yet another advantageous embodiment of the vehicle structure according to the first aspect, the section is a side sill section, the longitudinal extension of which is configured to extend in the longitudinal direction of the vehicle body of the vehicle and to be provided on the side of the vehicle body. An advantage of this embodiment is that an advantageous variant of the vehicle structure having a side sill section for impact absorption is provided, while maintaining or improving the rigidity and reinforcement of the vehicle structure. The innovative first reinforcing element is particularly advantageous for the side sill section of the vehicle structure, which must absorb impact in the event of a collision. However, in alternative embodiments, instead of a side sill section, the section or side section may be a side beam section, a bumper section, or a beam section configured to be located elsewhere in the vehicle.

[0037] According to an advantageous embodiment of the vehicle structure according to the first aspect, the side sill portion is configured to be attached to one or more cross beams of the vehicle body, which can further improve the rigidity of the vehicle structure.

[0038] The above features and embodiments of the vehicle structure can be combined in various possible ways to provide further advantageous embodiments.

[0039] According to a second aspect of the present invention, the above and other objects are achieved by a method for manufacturing a vehicle structure comprising a part having a longitudinal extension, the part comprising: a first member having a longitudinally extending portion extending in a longitudinal direction; a second member having a longitudinally extending portion extending in the longitudinal direction; Equipped with The first member is configured to face an interior side of the vehicle; The second member is configured to face an exterior of the vehicle; the first and second members are attached to each other such that the first and second members form a closed space; This method is manufacturing one or more tubular reinforcing members by one of hydroforming and hot gas forming; placing one or more tubular reinforcing members within the enclosed space; Includes:

[0040] An advantage of the method according to the second aspect is that the process for manufacturing the tubular reinforcing member is simplified relative to conventional solutions. Accordingly, an advantage of the method according to the second aspect is that the process for manufacturing a vehicle structure including the tubular reinforcing member is simplified. An advantage of the method according to the second aspect is that the weight and / or cost of the vehicle structure may be reduced while maintaining or improving the stiffness and stiffness of the vehicle structure.

[0041] Further advantageous embodiments of the vehicle structure according to the first aspect and the method according to the second aspect as well as further advantages of the embodiments of the invention emerge from the dependent claims and the detailed description of the embodiments.

[0042] The present invention will now be described in more detail, by way of example only, with reference to the enclosed drawings, in which like reference numerals are used for like parts throughout the embodiments. [Brief explanation of the drawings]

[0043] [Figure 1] 1 is a schematic top perspective view of a tubular reinforcing member of a first embodiment of a vehicle structure according to a first aspect of the present invention; FIG. [Figure 2] 2 is another schematic top perspective view of the tubular reinforcing member of FIG. 1. [Figure 3] 2 is a schematic side view of the tubular reinforcing member of FIG. 1. [Figure 4] 2 is another schematic side view of the tubular reinforcing member of FIG. 1. [Figure 5] 2 is a schematic top view of the tubular reinforcing member of FIG. 1. [Figure 6] 2 is a schematic bottom view of the tubular reinforcing member of FIG. 1. [Figure 7] 4 is a cross-sectional view of the tubular reinforcing member of FIG. 3 taken along line A-A. [Figure 8] 1 is a schematic exploded perspective view of a first embodiment of a vehicle structure according to a first aspect of the present invention; [Figure 9]FIG. 9 is a cross-sectional view of the assembled vehicle structure of FIG. 8. [Figure 10] 14 is a partial side view of the tubular reinforcing member of FIGS. 4 and 8 positioned within an enclosed space, showing multiple cross-sectional locations for the cross-sectional views of FIGS. 11-13. FIG. [Figure 11] 11 is a cross-sectional view of the assembled vehicle structure of FIG. 8 along D-D of FIG. 10. [Figure 12] 11 is a cross-sectional view of the assembled vehicle structure of FIG. 8 along E-E of FIG. 10. [Figure 13] 11 is a cross-sectional view of the assembled vehicle structure of FIG. 8 taken along line F-F of FIG. 10. [Figure 14] 11 is a cross-sectional view of the assembled vehicle structure of FIG. 8 along G-G of FIG. 10. [Figure 15] FIG. 10 is a schematic top perspective view of a tubular reinforcing member of a second embodiment of a vehicle structure according to the first aspect of the present invention; [Figure 16] 16 is another schematic top perspective view of the tubular reinforcing member of FIG. 15. [Figure 17] FIG. 16 is a schematic side view of the tubular reinforcing member of FIG. 15. [Figure 18] 16 is another schematic side view of the tubular reinforcing member of FIG. 15. [Figure 19] 16 is a schematic top view of the tubular reinforcing member of FIG. 15. [Figure 20] 16 is a schematic bottom view of the tubular reinforcing member of FIG. 15. FIG. [Figure 21] 18 is a cross-sectional view of the tubular reinforcing member of FIG. 17 along line B-B. [Figure 22] 1 is a schematic exploded perspective view of a first embodiment of a vehicle structure according to a first aspect of the present invention; [Figure 23] FIG. 23 is a cross-sectional view of the assembled vehicle structure of FIG. 22. [Figure 24] 25-28 are partial side views of the tubular reinforcing member of FIGS. 18 and 22 positioned within an enclosed space, showing multiple cross-sectional locations for the cross-sectional views of FIGS. 25-28. [Figure 25] 24 is a cross-sectional view of the assembled vehicle structure of FIG. 22 along D-D of FIG. 24. [Figure 26]24 is a cross-sectional view of the assembled vehicle structure of FIG. 22 along E-E in FIG. 24. [Figure 27] 24 is a cross-sectional view of the assembled vehicle structure of FIG. 22 along F-F of FIG. 24. [Figure 28] 24 is a cross-sectional view of the assembled vehicle structure of FIG. 22 along G-G in FIG. 24. [Figure 29] 4 is a schematic flow chart illustrating aspects of an embodiment of a method according to the second aspect of the present invention; DETAILED DESCRIPTION OF THE INVENTION

[0044] 1 to 14, a first embodiment of a vehicle structure 100 according to a first aspect of the invention and aspects of an embodiment of a vehicle structure according to a first aspect of the invention are shown schematically.

[0045] 8-14, a vehicle structure 100 includes a portion 102 having a longitudinally extending portion 104 (see FIG. 8) extending in a longitudinal direction 106. The portion 102 includes a first member 108 having a longitudinally extending portion 110 extending in the longitudinal direction 106 (see FIG. 8). The portion 102 includes a second member 112 having a longitudinally extending portion 114 extending in the longitudinal direction 106 (see FIG. 8). The first member 108 is configured to face an inner side 116 of the vehicle. The second member 112 is configured to face an outer side 118 of the vehicle. The first and second members 108, 112 are attached to each other such that the first and second members 108, 112 form an enclosed space 120. Thus, with the vehicle structure 100 installed, the first member 108 may face an interior side 116 of the vehicle, while the second member 112 may face an exterior side 118 of the same vehicle.

[0046] In this disclosure, "enclosed space" 120 also includes a substantially or essentially closed space. For example, one or more small openings may exist in the walls forming the enclosed space 120 and / or in the edges of the portion 102 of the vehicle structure 100, and the space 120 would still be considered closed. For example, the first and second members 108, 112 may be attached to one another by welding, such as laser welding, spot welding, or continuous welding, a mechanical locking structure such as rivets, an adhesive, or any other suitable fastening means.

[0047] 1-14, the portion 102 includes one or more tubular reinforcing members 122a positioned within the enclosed space 120. In the embodiment shown in FIGS. 8-14, the portion 102 includes one tubular reinforcing member 122a. However, in other embodiments, the portion 102 may include two or more tubular reinforcing members 122a. The tubular reinforcing member 122a has a longitudinal extension 124 (see FIG. 3) extending in the longitudinal direction 106. The tubular reinforcing member 122a is corrugated and includes corrugations 126, 128 (see FIGS. 1, 3, and 5). In some embodiments, the corrugations 126, 128 may be defined as including ridges 126 and grooves 128. In some embodiments, one or more of the ridges 126 and grooves 128 may be defined as extending at least partially across the longitudinal direction 106.

[0048] 1, 3 and 5, the tubular reinforcing member 122a includes two or more member sections 130a, 130b arranged side by side in the longitudinal direction 106. The two or more member sections 130a, 130b may be described as being arranged in series side by side in the longitudinal direction 106. One member section 130a of member sections 130a, 130b bulges outward in a first direction 132 (such as the upward direction 132) and a second direction 134 opposite to the first direction 132 (such as the downward direction 134), and bulges inward in a third direction 136 (such as the lateral direction 136), which is transverse to the first and second directions 132, 134, while another member section 130b of member sections 130a, 130b adjacent to said one member section 130a of member sections 130a, 130b bulges inward in the first and second directions 132, 134 and bulges outward in the third direction 136. Two member sections 130a, 130b adjacent to one another indicates that the other of the member sections 130a, 130b is adjacent to or in contact with the one of the member sections 130a, 130b. In some embodiments, the tubular reinforcing member 122a can include five or more member sections 130a, 130b, such as fifteen or more member sections 130a, 130b, arranged side by side in the longitudinal direction 106, or ten or more member sections 130a, 130b, for example, twenty or more member sections 130a, 130b.

[0049] In some embodiments, the corrugated tubular reinforcing member 122a may be defined or described as forming two or more corrugations, such as three or four corrugations, that are offset relative to one another in the longitudinal direction 106 or in the direction of the longitudinal extension 124 of the tubular reinforcing member 122a and / or that are not coincident with one another in the longitudinal direction 106. In some embodiments, the two or more corrugations may be defined or described as providing a zigzag or staggered structure or appearance of the corrugated tubular reinforcing member 122a and / or adjacent member sections 130a, 130b, for example, in the longitudinal direction 106. In some embodiments, the tubular reinforcing member 122a may be defined or described as having two or more longitudinal sides, such as three or four longitudinal sides, where one (or more) of the longitudinal sides of the tubular reinforcing member 122a bulges outward in one cross-section of the longitudinal extension 124 of the tubular reinforcing member 122a, while another (or two) of the longitudinal sides of the tubular reinforcing member 122a bulges inward in the same cross-section, and vice versa in subsequent cross-sections in the longitudinal direction 106. In some embodiments, when viewed in the longitudinal direction 106 or along a longitudinal side of the tubular reinforcing member 122a extending in the longitudinal direction 106, the corrugations of one of the longitudinal sides of the tubular reinforcing member 122a may be defined or described as being displaced in the longitudinal direction 106 relative to another one (or two) of the corrugations of the longitudinal sides of the tubular reinforcing member 122a, such as another adjacent longitudinal side, or two other adjacent longitudinal sides of the longitudinal sides.

[0050] 2, 4, and 5, in some embodiments, the tubular reinforcing member 122a can include one or more flattened regions 138 extending along substantially the entire longitudinal extension 124 of the tubular reinforcing member 122a. In the embodiment shown in FIGS. 1-14, the tubular reinforcing member 122a includes one flattened region 138 extending along substantially the entire longitudinal extension 124 of the tubular reinforcing member 122a. However, in other embodiments, the tubular reinforcing member 122a can include two or more flattened regions, e.g., spaced apart. In some embodiments, the flattened region 138 can be used for attachment of the tubular reinforcing member 122a to one of the first and second members 108, 112 by welding, e.g., laser welding, spot welding, or continuous welding; a mechanical locking structure such as a rivet; an adhesive; or any other suitable fastening means. In some embodiments, in addition to or instead of the above-described flat region 138, the tubular reinforcing member 122a may include one or more flat regions 140, i.e., planar regions, e.g., outside of the above-described flat region 138, for attachment of the tubular reinforcing member 122a to one or more of the first and second members 108, 112 by welding, e.g., laser welding or spot welding, mechanical locking structures such as rivets, adhesive, or any other suitable fastening means.

[0051] 1-14, in some embodiments, member sections 130a, 130b may form one or more corrugations extending in the longitudinal direction 106 along the longitudinal extension 124 of tubular reinforcing member 122a. In some embodiments, member sections 130a, 130b may be defined as forming or constructing tubular reinforcing member 122a.

[0052] 1, 2, 4, and 5, in some embodiments, the tubular reinforcing member 122a may form one or more welding openings 142, 144 for attaching the tubular reinforcing member 122a to one or more of the first and second members 108, 112, for example, by laser welding or spot welding. The openings 142, 144 may be located at one of the two ends of the tubular reinforcing member 122a or anywhere between the two ends of the tubular reinforcing member 122a.

[0053] 1-14, in some alternative embodiments, instead of a flat region 138 extending along the entire longitudinal extension 124 of the tubular reinforcing member 122a, one of the member sections 130a, 130b bulges outward in the first and second directions 132, 134 and bulges inward in a third direction 136 and a fourth direction 146 opposite the third direction 136 (e.g., another lateral direction 146), while another of the member sections 130a, 130b adjacent to the one of the member sections 130a, 130b bulges inward in the first and second directions 132, 134 and bulges outward in the third and fourth directions 136, 146. In some alternative embodiments, the corrugations 126, 128 of the tubular reinforcing member 122a may include an annular ridge, and one of the outwardly and inwardly flaring member sections 130a, 130b and the other of the member sections 130a, 130b together have the same one of the annular ridges. The annular ridge may extend at least partially across the longitudinal direction 106. In some alternative embodiments, the corrugations 126, 128 of the tubular reinforcing member 122a may include annular grooves, and one of the outwardly and inwardly flaring member sections 130a, 130b and the other of the member sections 130a, 130b together have the same one of the annular grooves. The annular grooves may extend at least partially across the longitudinal direction 106. The annular ridges and annular grooves may form one or more corrugations extending in the longitudinal direction 106 along the longitudinal extension 124 of the tubular reinforcing member 122a. The annular ridges and annular grooves may form the tubular reinforcing member 122a. Even in alternative embodiments without the flat regions 138, the tubular reinforcing member 122a may include one or more of said flat regions 140 for attachment of the tubular reinforcing member 122a to one or more of the first and second members 108, 112.

[0054] 1, 3, and 9, the longitudinal extension 124 of the tubular reinforcing member 122a may be described as extending in the direction 106 of a central longitudinal axis 148 encompassed by the tubular reinforcing member 122a. The three or four directions 132, 134, 136, 146 may be relative to or relative to the central longitudinal axis 148. The terms "outward" and "inward" mentioned above may be relative to the central longitudinal axis 148. "Outward" may be a direction away from the central longitudinal axis 148, while "inward" may be a direction toward the central longitudinal axis 148.

[0055] 15 to 28, there is shown schematically a second embodiment of a vehicle structure 300 according to the first aspect of the invention and further aspects of the embodiment of the vehicle structure according to the first aspect of the invention. Some features of the second embodiment of the vehicle structure 300 may correspond to features of the first embodiment of the vehicle structure 100 of Figures 1 to 14 and will not be repeated here to avoid repetition. The vehicle structure 300 of Figures 15 to 28 differs from the vehicle structure 100 of Figures 1 to 14 in that one member section 130a of member sections 130a, 130b has a tubular reinforcing member 122b configured to bulge outward and inward in first and second directions 132, 134 and bulge inward in a third direction 136, while another member section 130b of member sections 130a, 130b adjacent to said one member section 130a of member sections 130a, 130b has a tubular reinforcing member 122b configured to bulge inward and outward in the first and second directions 132, 134 and bulge outward in the third direction 136. In some alternative embodiments, instead of a flat region 138 extending along the entire longitudinal extension 124 of the tubular reinforcing member 122b, one of the member sections 130a, 130b bulges outward and inward in the first and second directions 132, 134 and bulges inward in the third and fourth directions 136, 146, while another of the member sections 130a, 130b adjacent to the one of the member sections 130a, 130b bulges inward and outward in the first and second directions 132, 134 and bulges outward in the third and fourth directions 136, 146.

[0056] In some embodiments, grooves 128 may be described as being formed when member sections 130a, 130b bulge inward. Ridges 126 may be described as being formed when member sections 130a, 130b bulge outward.

[0057] 1-28 , in some embodiments, the tubular reinforcing members 122a-b may be hydroformed, hot gas formed, extruded, molded from one or more plates, hot-pressed from one or more plates, or cold-worked from one or more plates. However, other ways of manufacturing the tubular reinforcing members 122a-b are possible. In some embodiments, the tubular reinforcing members 122a-b may be made of a material including or consisting of a metal or metal alloy, such as aluminum or steel, or a material including aluminum or steel. In some embodiments, the tubular reinforcing members 122a-b may be made of a material including or consisting of a polymer or a polymer composite, such as a fiber-reinforced polymer, e.g., carbon fiber-reinforced polymer (CFRP). However, other materials are possible. One or more of the first and second members 108, 112 may be formed from a plate, hot-pressed from one or more plates, or cold-worked from one or more plates. One or more of the first and second members 108, 112 may be made of a material that includes or consists of a metal or metal alloy, such as aluminum. However, other materials are possible. In some embodiments, one or more of the first and second members 108, 112 may include one of the group consisting of a hat-shaped profile and a U-shaped profile.

[0058] In some embodiments, the following types of materials may be used for the tubular reinforcing members 122a-b and one or more of the first and second members 108, 112, or for any other elements or members included in the vehicle structure 100, 300:

[0059] There are several known ultra-high strength steels (UHSS) for hot stamping and quenching. For example, the blank can be made of coated or uncoated boron steel, such as Usibor® (22MnB5) available from ArcelorMittal.

[0060] Usibor® 1500P is an example of a 22MnB5 steel. The composition of Usibor® is summarized below in weight percentages (the balance being iron (Fe) and inevitable impurities): Maximum carbon (C) (%): 0.25 Maximum silicon (Si) (%): 0.4 Maximum manganese (Mn) (%): 1.4 Maximum phosphorus (P) (%): 0.03 Maximum sulfur (S) (%): 0.01 Aluminum (Al) (%): 0.01 to 0.1 Maximum Titanium (Ti) (%): 0.05 Maximum Niobium (Nb) (%): 0.01 Maximum copper (Cu)(%):0.20 Maximum boron (B) (%): 0.005 Maximum Chromium (Cr) (%): 0.35

[0061] Usibor® 1500P may have a yield strength of, for example, 1100 MPa and an ultimate tensile strength of 1500 MPa.

[0062] Usibor® 2000 is another boron steel with even higher strength. The yield strength of Usibor® 2000 can be greater than 1400 MPa, and the ultimate tensile strength can exceed 1800 MPa. The composition of Usibor® 2000 is summarized below by weight percentage (the balance is iron (Fe) and impurities): Maximum carbon (C) (%): 0.36 Maximum silicon (Si) (%): 0.8 Maximum manganese (Mn) (%): 0.8 Maximum phosphorus (P) (%): 0.03 Maximum sulfur (S) (%): 0.01 Aluminum (Al) (%): 0.01 to 0.06 Maximum Titanium (Ti) (%): 0.07 Maximum Niobium (Nb) (%): 0.07 Maximum copper (Cu)(%):0.20 Maximum boron (B) (%): 0.005 Maximum Chromium (Cr) (%): 0.50 Maximum Molybdenum (Mb) (%): 0.50

[0063] In addition to the ultra-high strength steels mentioned above, higher ductility steels may also be used for parts of the structural framework where energy absorption is required. These steels may be used in hot stamping processes, but the process does not result in a martensitic microstructure. Examples of suitable higher ductility steels include Ductibor® 500, Ductibor® 1000, and CRL-340LA.

[0064] Another material used in hot stamping is Ductibor® 500. Ductibor® 500 is a much more ductile steel material, which can be effective at absorbing energy during impact. The yield strength of Ductibor® 500 can be greater than 400 MPa and the ultimate tensile strength can be greater than 550 MPa.

[0065] The composition of Ductibor® 500 is summarized below in weight percentages (the balance being iron (Fe) and impurities): Maximum carbon (C) (%): 0.1 Maximum silicon (Si) (%): 0.5 Maximum manganese (Mn) (%): 1.7 Maximum phosphorus (P) (%): 0.03 Maximum sulfur (S) (%): 0.025 Aluminum (Al) (%): 0.015 to 0.2 Maximum Titanium (Ti) (%): 0.09 Maximum Niobium (Nb) (%): 0.10 Maximum copper (Cu)(%):0.20 Maximum boron (B) (%): 0.001 Maximum Chromium (Cr) (%): 0.20

[0066] Ductibor® 1000 is another material used in hot stamping to increase elongation when compared to Usibor® 1500 and Usibor® 2000. The yield strength of Ductibor® 1000 can be greater than 800 MPa and the ultimate tensile strength can be greater than 1000 MPa. The composition of Ductibor® 1000 is summarized below by weight percentage (the balance is iron (Fe) and impurities): Maximum carbon (C) (%): 0.10 Maximum silicon (Si) (%): 0.6 Maximum manganese (Mn) (%): 1.8 Maximum phosphorus (P) (%): 0.03 Maximum sulfur (S) (%): 0.01 Aluminum (Al) (%): 0.01 to 0.1 Maximum Titanium (Ti) (%): 0.05 Maximum Niobium (Nb) (%): 0.10 Maximum copper (Cu)(%):0.20 Maximum boron (B) (%): 0.005 Maximum Chromium (Cr) (%): 0.20

[0067] Each of the above-described vehicle structures 100, 300 may be a vehicle side structure, and the respective portion 102 may be a side portion. However, the vehicle structures 100, 300 may be applied and attached elsewhere on the vehicle, for example, to the front of the vehicle where they form part of a bumper, to the rear of the vehicle, or elsewhere within the vehicle. The vehicle structures 100, 300 may be used, for example, in electric or hybrid vehicles, but may also be used in conventional vehicles equipped with only a combustion engine. The vehicle structures 100, 300 may be configured to protect one or more electric batteries of an electric or hybrid vehicle, for example, during a collision. Thus, the vehicle structures 100, 300 may be located on one or more sides of the electric battery. The vehicle structures 100, 300 are effective in protecting the driver and / or one or more occupants of the vehicle during a collision. The vehicle structures 100, 300 are effective as protection against pole collisions or crashes. The vehicle structures 100, 300 are effective in preventing the pole from penetrating into the vehicle interior during a pole collision.

[0068] In some embodiments, portion 102 is a side sill portion, and a longitudinal extension 104 of side sill portion 102 is configured to extend in a longitudinal direction 106 of a vehicle body of a vehicle and is configured to be provided on a side of the vehicle body. Referring to FIG. 9 , in some embodiments, side sill portion 102 may be configured to be attached or attachable to one or more cross beams 400 of the vehicle body, for example, two cross beams of the vehicle body. However, in alternative embodiments, instead of a side sill portion, portion or side portion may be a side beam portion, a bumper portion, or a beam portion configured to be located elsewhere in the vehicle.

[0069] The features of the different embodiments of the vehicle structure disclosed above can be combined in various possible ways to provide further advantageous embodiments.

[0070] Referring to Figure 29, aspects of an embodiment of a method for manufacturing a vehicle structure 100, 300 according to a second aspect of the invention, comprising a portion 102 having a longitudinal extension extending in a longitudinal direction 104, is shown schematically in a flow chart, a first member 108 having a longitudinally extending portion 110 extending in a longitudinal direction 106; a second member 112 having a longitudinally extending portion 114 extending in the longitudinal direction 106; Including, The first member 108 is configured to face the interior side 116 of the vehicle; The second member 112 is configured to face the exterior 118 of the vehicle; The first and second members 108, 112 are attached to one another such that the first and second members 108, 112 form a closed space 120; This method is Step 501 of manufacturing one or more tubular reinforcing members 122a-b by one of hydroforming and hot gas forming; Step 502 of placing one or more tubular reinforcing members 122a-b within the enclosed space 120; Includes:

[0071] The invention is not limited to the above-described embodiments, but instead relates to and encompasses all different embodiments falling within the scope of the attached independent claims.

Claims

1. A vehicle structure (100, 300) comprising a portion (102) having a longitudinal extension (104) extending in a longitudinal direction (106), the portion (102) comprising: a first member (108) having a longitudinally extending portion (110) extending in the longitudinal direction (106); a second member (112) having a longitudinally extending portion (114) extending in the longitudinal direction (106); Equipped with The first member (108) is configured to face an interior side (116) of the vehicle; The second member (112) is configured to face an exterior (118) of the vehicle; the first and second members (108, 112) are attached to one another such that the first and second members (108, 112) form a closed space (120); the portion (102) comprises one or more tubular reinforcing members (122a, 122b) located within the enclosed space (120); The tubular reinforcing members (122a, 122b) have longitudinally extending portions (124) extending in the longitudinal direction (106), The tubular reinforcing members (122a, 122b) are corrugated and have corrugated portions (126, 128); the tubular reinforcing member (122a, 122b) comprises two or more member sections (130a, 130b) arranged side by side in the longitudinal direction (106); One (130a) of the member sections (130a, 130b) bulges outward in a first direction (132) and a second direction (134) opposite the first direction (132) and bulges inward in a third direction (136) transverse to the first and second directions (132, 134), while another one (130b) of the member sections (130a, 130b) adjacent to the one (130a) of the member sections (130a, 130b) bulges inward in the first and second directions (132, 134) and bulges outward in the third direction (136); A vehicle structure (100, 300).

2. 2. The vehicle structure of claim 1, wherein the tubular reinforcing member comprises one or more flat regions extending along the entire longitudinal extension of the tubular reinforcing member.

3. One (130a) of the member sections (130a, 130b) bulges outwardly and inwardly in the first and second directions (132, 134) and bulges inwardly in the third direction (136), while 3. The vehicle structure (300) of claim 1 or 2, wherein another one (130b) of the member sections (130a, 130b) adjacent to the one (130a) of the member sections (130a, 130b) bulges inward and outward in the first and second directions (132, 134) and bulges outward in the third direction (136).

4. one (130a) of said member sections (130a, 130b) bulges outward in said first and second directions (132, 134) and bulges inward in said third direction (136) and a fourth direction (146) opposite said third direction (136); 2. The vehicle structure (100, 300) of claim 1, wherein another one (130b) of the member sections (130a, 130b) adjacent to the one (130a) of the member sections (130a, 130b) bulges inward in the first and second directions (132, 134) and bulges outward in the third and fourth directions (136, 146).

5. the corrugated portions (126, 128) of the tubular reinforcing members (122a, 122b) include annular ridges; 5. The vehicle structure (100, 300) of claim 4, wherein the one (130a) of the outwardly and inwardly bulging member sections (130a, 130b) and the other (130b) of the member sections (130a, 130b) together comprise the same one of the annular ridges.

6. 6. The vehicle structure (100, 300) of claim 5, wherein the annular ridge extends at least partially transverse to the longitudinal direction (106).

7. the corrugated portions (126, 128) of the tubular reinforcing members (122a, 122b) include annular grooves; 7. The vehicle structure (100, 300) according to claim 4, wherein the one (130a) of the outwardly and inwardly bulging member sections (130a, 130b) and the other (130b) of the member sections (130a, 130b) together have the same one of the annular grooves.

8. 8. The vehicle structure (100, 300) of claim 7, wherein the annular groove extends at least partially transverse to the longitudinal direction (106).

9. 9. The vehicle structure (100, 300) of claim 7 or 8, wherein the annular ridge and the annular groove form one or more corrugations extending in the longitudinal direction (106) along the longitudinal extension (124) of the tubular reinforcing member (122a, 122b).

10. one (130a) of said member sections (130a, 130b) bulges outwardly and inwardly in said first and second directions (132, 134) and inwardly in said third and fourth directions (136, 146), while 10. A vehicle structure (300) according to any one of claims 4 to 9, wherein another one (130b) of the member sections (130a, 130b) adjacent to the one (130a) of the member sections (130a, 130b) bulges inward and outward in the first and second directions (132, 134) and bulges outward in the third and fourth directions (136, 146).

11. 11. The vehicle structure (100, 300) of claim 4, wherein the tubular reinforcing member (122a, 122b) comprises one or more flat regions (140) for attachment of the tubular reinforcing member (122a, 122b) to one or more of the first and second members (108, 112).

12. 12. The vehicle structure (100) of claim 1, wherein the member sections (130a, 130b) form one or more corrugations extending in the longitudinal direction (106) along the longitudinal extension (124) of the tubular reinforcing member (122a, 122b).

13. 13. The vehicle structure (100) of claim 1, wherein the tubular reinforcing member (122, 122b) defines one or more openings (142, 144) for welding to attach the tubular reinforcing member (122a, 122b) to one or more of the first and second members (108, 112).

14. The vehicle structure (100) of any one of claims 1 to 13, wherein the tubular reinforcing members (122a, 122b) are hydroformed, hot gas formed, extruded, or formed from one or more plates.

15. A method for manufacturing a vehicle structure (100, 300) comprising a portion (102) having a longitudinal extension (104) extending in a longitudinal direction (106), the portion (102) comprising: a first member (108) having a longitudinally extending portion (110) extending in the longitudinal direction (106); a second member (112) having a longitudinally extending portion (114) extending in the longitudinal direction (106); Equipped with The first member (108) is configured to face an interior side (116) of the vehicle; The second member (112) is configured to face an exterior (118) of the vehicle; the first and second members (108, 112) are attached to one another such that the first and second members (108, 112) form a closed space (120); The method comprises: manufacturing (501) one or more tubular reinforcing members (122a, 122b) by one of hydroforming and hot gas forming; placing (502) the one or more tubular reinforcing members (122a, 122b) within the enclosed space (120); A method comprising:

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