Vehicle body side structural frame

Abstract

A method for manufacturing a unitary body side structural frame of a vehicle is provided.SOLUTION: The method comprises the steps of providing a plurality of blanks and joining the blanks together to form a composite blank. The step of joining the blanks comprises partially overlapping the two blanks, thereby forming one or more overlapping areas. The method also comprises deforming the composite blank to form the unitary body side structural frame. There is also provided a unitary body side structural frame as obtainable by any of the methods described herein.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] This application claims the benefit of and rights of European Patent Application No. 18382467.1 filed June 25, 2018.

[0002] The present invention relates to a vehicle body side structural frame and a method for manufacturing a vehicle body side structural frame. [Background technology]

[0003] A vehicle, such as an automobile, includes a structural framework that withstands all loads that the vehicle may be subjected to during its lifespan. The structural framework is also configured to withstand and absorb impacts, for example, in the event of contact with another vehicle or an obstacle.

[0004] The structural framework of a vehicle, e.g., an automobile, in this regard may include bumpers, pillars (A-pillar, B-pillar, C-pillar, D-pillar), side impact beams, rockers or sills, hinge pillars, and shock absorbers. The body side structural frame generally includes rocker panels, hinge pillars, A-pillar, and B-pillar. The body side structural frame also includes C-pillar and D-pillar.

[0005] In some examples, the body side structural frame can be formed by connecting multiple structural components around the door, for example, connecting a pre-formed B-pillar lower part to a pre-formed rocker, a B-pillar upper part to a pre-formed A-pillar and / or C-pillar, a pre-formed hinge pillar lower part to the rocker, and a hinge pillar upper part to the A-pillar and / or C-pillar.

[0006] Such structural members may be formed by one or more plates joined together. For example, a B-pillar may be formed by a central reinforcement B-pillar, an inner plate, and in some instances an outer plate. The central reinforcement, inner plate, and outer plate may be joined at their respective 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 supplier or by different suppliers, for joining to form a bodyside structural frame.

[0007] In another example, the body side structural frame may be formed as a one-piece structure and supplied to the vehicle manufacturer. According to this aspect, the body side structural frame may be formed by joining, e.g., welding, different blanks to form and shape a composite blank, e.g., by hot or cold forming.

[0008] U.S. Patent Publication No. 2006 / 0097549 shows an example of this type of one-piece body side structural frame and a method for manufacturing the same. This publication shows an automobile side panel including a bottom sill member, a roof panel section, and a plurality of pillars extending between the sill member and the roof panel section. The sill member of this publication is formed from a sheet metal blank made of high-strength steel, with the pillars and roof panel section forming a single structure, and has at least one area that is locally stiffened and therefore subject to increased loads during a vehicle collision.

[0009] The welding of different blanks to form a composite blank and the shaping of the composite blank is commonly referred to as tailor welded blank (TWB). Blanks of different thicknesses, sizes, materials, or properties can be joined to form a composite blank to minimize the weight of the component while adhering to structural requirements. The blanks are welded "end to end" ("butt joint").

[0010] These tailored blanks are typically designed to be hot forged and then manufactured to form automotive components, such as body side structural frames. However, such tailored 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 tensile strengths of at least 1000 MPa, preferably about 1500 MPa, or up to 2000 MPa or more.

[0011] An example of a steel used in the hot forging process is 22MnB5 steel. 22MnB5 steel is supplied in the ferrite-pearlite phase. The mechanical properties are related to this structure. After heating, the blank is hot formed and quenched. This process is known as press hardening. Such a process allows the formation of a predominantly martensitic structure. As a result, the ultimate tensile strength and yield strength are significantly increased.

[0012] Usibor® 1500P is an example of a 22MnB5 steel. The composition of Usibor® is summarized in the following weight percentages (the remainder is iron (Fe) and unavoidable impurities):

[0013] [Table 1]

[0014] Usibor® 1500P, for example, may have a yield strength of 1100 MPa and an ultimate tensile strength of 1500 MPa.

[0015] Usibor® 2000 is another boron steel with greater strength. Usibor® 2000 may have a yield strength of 1400 MPa and an ultimate tensile strength greater than 1800 MPa. Usibor® 2000's composition includes, by weight, 0.37% maximum carbon, 1.4% maximum manganese, 0.7% maximum silicon, and 0.005% maximum boron.

[0016] Various other UHSS steel compositions may also be used in the automotive industry. In particular, the steel compositions described in EP 2 735 620 A1 may be considered suitable. Reference is made in particular to Table 1 and paragraphs 0016 to 0021 of EP 2 735 620 A1. Paragraphs 0067 to 0079 are also taken into consideration.

[0017] In some examples, the UHSS blank may include approximately 0.22% carbon, 1.2% silicon, and 2.2% manganese by weight.

[0018] In some other examples, the UHSS blank may include, by weight, 0.17-0.23% carbon, up to 2.5% manganese, up to 0.5% silicon, and 0.002-0.005% boron.

[0019] Another material used in hot forging is Ductibor® 500. Ductibor® 500 is a steel material with greater ductility. These steel materials may also be effective at absorbing energy during impact. Ductibor® 500 may have a yield strength of 400 MPa or greater and an ultimate tensile strength of 550 MPa or greater.

[0020] The composition of Ductibor® 500 includes max. 0.1% carbon, max. 1.3% manganese, max. 0.5% silicon, and max. 0.001% boron.

[0021] Ductibor® 1000 is another material used in hot forging to increase elongation compared to Usibor® 1500 and Usibor® 2000. The yield strength of Ductibor® 1000 may be greater than 800 MPa, and the ultimate tensile strength may be greater than 1000 MPa. The composition of Ductibor® 1000 includes 0.12% maximum carbon, 2% maximum manganese, 0.75% maximum silicon, and 0.005% maximum boron.

[0022] To prevent decarburization and scale formation during the forming process, as well as corrosion and oxidation damage, steels of any of these compositions (e.g., 22MnB5 steels such as Usibor® and other compositions mentioned above) are provided with a coating, which may be, for example, an aluminum-silicon (AlSi) coating, or a coating primarily comprising zinc or a zinc alloy.

[0023] On the other hand, aluminum-silicon coatings have a significant drawback with regard to welding behavior: when blanks with aluminum-silicon coatings are welded without other means to form tailor-welded blanks (TWBs), the aluminum of the coating can get into the weld zone, which can cause a significant deterioration in the mechanical properties of the resulting component and increase the likelihood of fracture in the weld zone.

[0024] To overcome these problems, it is known to remove part of the coating in the area close to the welding area by laser ablation. This method has the disadvantage that an additional step is required for the production of (tailored or composite) blanks and components, which, despite the repetitive nature of the process, requires a complex quality process with many parts that end up being discarded. This disadvantage is accompanied by an increase in the cost of the welding step, limiting the competitiveness of the technology in the industry.

[0025] In the prior art, other methods have been developed to avoid the coating ablation step, but these methods require the use of additional powder or wire to prevent aluminum from being present throughout the weld area.

[0026] After forming the one-piece bodyside structural frame, the one-piece bodyside structural frame can be joined, e.g., welded, to the remaining portions of the vehicle's structural framework, such as the inner plate of at least one of the A-pillar, B-pillar, C-pillar, hinge pillar, and rocker. For example, the lower portion of the one-piece bodyside structural frame can be connected to the lower flange of the rocker inner plate. Also, the upper portion of the one-piece bodyside structural frame can be connected to the upper flange of the A-pillar and / or C-pillar inner plate. Thus, the one-piece bodyside structural frame formed in this manner can correspond to an "outer" panel. This "outer" panel can be supplemented by the A-pillar inner plate, B-pillar inner plate, C-pillar inner plate, hinge pillar inner plate, and / or rocker inner plate.

[0027] On the other hand, this method does not completely close a portion of the A-pillar. The lower flange of the inner panel of the A-pillar and the integral bodyside structural frame do not fit together along the entire length. That is, a gap exists in a portion of the A-pillar. This gap may occur substantially rearward of the B-pillar, particularly in the region of the A-pillar located rearward of the center of the B-pillar, i.e., in the region corresponding to the U-shaped portion of the B-pillar. Similarly, the upper flange of the inner panel of the rocker and the bodyside structural frame do not meet along the entire length of the rocker. This may occur in the region of the rocker located substantially rearward of the B-pillar and / or hinge pillar. Therefore, a portion of the rocker may not completely close.

[0028] According to these embodiments, there are portions of the A-pillar and / or rocker that are not completely closed. That is, the A-pillar and / or rocker do not form a closed section together with the respective inner plate. Therefore, such sections may have less strength than a solution in which the inner and outer panels are welded along the entire length via both the upper and lower flanges. That is, in such sections, the pillar and rocker are first deformed and then attached to the remaining parts of the vehicle's structural framework. Such sections with reduced strength may result in a reduction in the structural behavior of the vehicle in a collision. Meanwhile, to ensure good functional behavior of the side structural frame with respect 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 along the entire section that simultaneously ensures, for example, the proper positioning of a rubber seal of the body side structural frame between the side structural frame and one or more inner plates.

[0029] The present invention provides exemplary systems and methods that at least partially address some of the disadvantages discussed above. Summary of the Invention

[0030] In a first aspect, a method for manufacturing a one-piece bodyside structural frame for a vehicle is provided. The method includes providing a plurality of blanks and joining the blanks to form a composite blank. The joining of the blanks includes partially overlapping at least two blanks to form one or more overlapping areas. The method also includes deforming the composite blanks to form the one-piece bodyside structural frame. The one-piece bodyside structural frame includes a lower beam section, an upper beam section, a front pillar section connecting the lower beam section to the upper beam section, and a rear pillar section connecting the lower beam section to the upper beam section.

[0031] This embodiment increases the thickness of some areas of the one-piece bodyside structural frame, thereby increasing the strength of the one-piece bodyside structural frame. Because the overlaps are precisely formed in the required areas, the overall weight of the one-piece bodyside structural frame and the number of weld lines can be reduced compared to solutions in which the overall thickness of a single blank is increased by increasing the thickness in one or more overlapping areas.

[0032] In this invention, two partially overlapping blanks indicates that only a portion of the two blanks overlap.

[0033] The lower beam portion may be a rocker 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 perpendicularly from the lower beam portion to the upper beam portion. Thus, the one-piece body side structural frame may define a door opening for 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 one-piece body side structural frame is also referred to as a "one-piece door ring" or "one-piece door ring."

[0034] In this invention, rockers, A-pillars, B-pillars, C-pillars, and hinge pillars are described as follows: A rocker or sill is a substantially horizontally oriented component extending from the rear part of the vehicle toward the front part, below the door opening. A B-pillar is a vertically oriented component extending from the vehicle floor toward the roof. The B-pillar is located in the center region of the vehicle and generally separates the front door opening from the rear door opening. A hinge pillar is a vertical body extending substantially from the vehicle floor toward the engine hood or windscreen. Front door hinges are generally attached to the hinge pillar. An A-pillar is an arcuate body extending substantially parallel to a portion of the roof panel and a portion of the front windscreen in the upper region of the door opening. The A-pillar extends from the top of the B-pillar toward the top of the hinge pillar. In some configurations, the A-pillar may extend below the B-pillar. A C-pillar is a structure rearward of the vehicle's rear door and extends upward from the rocker portion. In some embodiments, the C-pillar may extend substantially vertically from the rocker toward the A-pillar (if the A-pillar extends lower than the B-pillar). In other embodiments, the C-pillar includes a substantially vertical portion and an arcuate portion that extend substantially parallel to a portion of the roof panel and the upper region of the rear door opening to fit over the B-pillar.

[0035] In some embodiments, the B-pillar, A-pillar, hinge pillar, and rocker may form a door frame, thus forming a unitary body side structural frame for the front door opening.

[0036] In another embodiment, a one-piece body side structural frame can be formed by connecting the lower part of the B-pillar to the rocker, the upper part of the B-pillar to the upper part of the C-pillar, and the lower part of the C-pillar to the rocker, thus forming a frame for the rear door opening.

[0037] In other embodiments, the integral body side structural frame may surround the front and rear door openings of the vehicle. In these embodiments, the rocker may connect to the hinge pillar and the C-pillar, while the A-pillar may connect the hinge pillar to the C-pillar. In some of these embodiments, the integral body side structural frame also includes the B-pillar.

[0038] In all of these embodiments, the integral bodyside structural frame may be an outer frame. Thus, the integral outer bodyside structural frame may be joined to the remainder of the vehicle's structure. Alternatively, the integral bodyside structural frame may be an inner frame. Such an integral inner frame may be joined to the outer frame.

[0039] When the body side structural frame is formed as a one-piece structure, the boundaries between the different pillars are unclear due to the unitary structure, and therefore, reference numerals are used herein to designate the portions of the one-piece structure that are considered to form the B-pillar, A-pillar, C-pillar, etc.

[0040] The transition between the beam and pillar sections is the region where the pillar section meets the beam section, ie, the region that changes from a substantially horizontally shaped body to a substantially vertical body.

[0041] Thus, the transition between the B-pillar section and the rocker section is the area where the B-pillar section meets the rocker section, i.e., the area where the body changes from a substantially horizontally formed body to a substantially vertical body. The transitions between the A-pillar section and the B-pillar section, the A-pillar section and the hinge-pillar section, and the hinge-pillar section and the rocker section may be similarly formed. Similarly, the transitions between the C-pillar section and the A-pillar section, the C-pillar section and the B-pillar section, and the C-pillar section and the rocker section may also be formed.

[0042] One or more overlapping areas may be formed to prevent material loss and strength reduction that may occur in portions of the one-piece bodyside structural frame compared to solutions in which structural components are first formed and then joined to form the bodyside structural frame.

[0043] In some embodiments, at least one of the overlapping areas may substantially correspond to a transition between a beam section, such as a lower beam section or an upper beam section, and a pillar section, such as a front pillar section or a rear pillar section of a monolithic frame. This indicates that one overlapping area may correspond to a transition between a rear pillar section, such as a B-pillar section or a C-pillar section, and a lower beam section, such as a rocker section, a transition between a rear pillar section and an upper beam section, a transition between a front pillar section, such as a hinge pillar section or a B-pillar section, and a lower beam section, or a transition between a front pillar section and an upper beam section.

[0044] Alternatively, or in addition, overlaps may be formed in locations where high loads are expected. For example, overlaps may be formed in beam and / or pillar sections. In some of these embodiments, at least one of the overlap areas may be formed in an upper beam section, such as an A-pillar section or a C-pillar section.

[0045] In some embodiments, joining the blanks together may comprise welding the blanks together in the overlapping area. By joining the blanks together in the overlapping area, it is not necessary to remove a portion of the coating in the area near the welding area or to use powder or wire material. Therefore, the efficiency of the manufacturing process may be improved, and costs may be reduced. Optionally, the welding of the blanks may comprise spot welding. In other embodiments, alternative welding techniques, such as remote laser welding, may be used. In other embodiments, the blanks may be joined by other suitable methods, such as adhesives.

[0046] In some embodiments, the integral body side structural frame may be a front frame. In these embodiments, the lower beam section may comprise a rocker section. The upper beam section may comprise an A-pillar section. The front pillar section may comprise a hinge pillar section. The rear pillar section may comprise a B-pillar section.

[0047] One or more overlapping areas may be formed in areas of the integral side structural frame that are subject to high loads during a side impact, such as the transition between the B-pillar and the rocker and / or the transition between the B-pillar and the A-pillar.

[0048] In some of these embodiments, one of the overlapping areas may substantially correspond to the transition between the rocker section and the B-pillar section, i.e., the area where the transition occurs from a substantially horizontal configuration to a substantially vertical configuration. In this manner, the loss of strength caused by the gap formed between the rocker inner plate and the bottom of the B-pillar U-section may be compensated for by the increased thickness provided by the overlapping area. Thus, the portion of the integral bodyside structural frame extending from the rocker section toward the B-pillar section is reinforced.

[0049] Alternatively, or additionally, one of the overlapping areas may substantially correspond to the transition between the B-pillar portion and the A-pillar portion, resulting in a reinforcement of the portion of the integral body side structural frame extending from the B-pillar portion toward the A-pillar portion.

[0050] In some embodiments, one of the overlapping areas may substantially correspond to the transition between the A-pillar portion and the hinge-pillar portion, and such overlapping area may provide additional stiffness to the structural frame, particularly in the portion extending from the hinge portion toward the A-pillar portion.

[0051] Additionally, one of the overlapping areas may substantially correspond to the transition between the rocker portion and the hinge portion.

[0052] Additionally or alternatively, one of the overlapping areas may be formed within the A-pillar portion.

[0053] The integral bodyside structural frame may have multiple overlapping areas. For example, the B-pillar section may have one overlapping area formed at the lower part of the B-pillar section, i.e., the transition between the rocker section and the B-pillar section, and another overlapping area formed at the upper part of the B-pillar section, i.e., the transition between the B-pillar and the A-pillar section. This may increase the rigidity of the B-pillar section and the integral bodyside structural frame as a whole.

[0054] In some alternative embodiments, the integral body side structural frame may be a rear frame. In these embodiments, the front pillar section may comprise a B-pillar section. The lower beam section may comprise a rocker section. The upper beam section and rear pillar section may comprise a C-pillar section extending from the rocker section toward the B-pillar section.

[0055] In some of these embodiments, one of the overlapping areas may correspond substantially to the transition between the rocker portion and the B-pillar portion.

[0056] Alternatively, or additionally, one of the overlapping areas may correspond substantially to the transition between the B-pillar portion and the C-pillar portion.

[0057] In another embodiment, one of the overlapping areas may substantially correspond to the transition between the C-pillar portion and the rocker portion.

[0058] In some other embodiments, the one-piece body side structural frame may be a frame that surrounds a single opening for both the front and rear doors of the vehicle. In these embodiments, the lower beam section may comprise a rocker section. The front pillar section may comprise a hinge pillar section. The rear pillar section may comprise a C-pillar section. The upper beam section may comprise an A-pillar section. Thus, the A-pillar section may extend from the hinge pillar section toward the C-pillar section. And, the C-pillar section may extend from the rocker section toward the A-pillar section.

[0059] In this invention, the overlapping area between the B-pillar and the rocker is interpreted as an overlapping area that substantially corresponds to or is provided at the transition portion between the B-pillar portion and the rocker portion. The overlapping area between the A-pillar and the B-pillar is interpreted as an overlapping area that substantially corresponds to or is provided at the transition portion between the A-pillar portion and the B-pillar portion. The overlapping area between the A-pillar and the hinge is interpreted as an overlapping area that substantially corresponds to or is provided at the transition portion between the A-pillar portion and the hinge-pillar portion. The overlapping area between the hinge and the rocker is interpreted as an overlapping area that substantially corresponds to or is provided at the transition portion between the hinge-pillar portion and the rocker portion. The overlapping area between the C-pillar and the rocker is interpreted as an overlapping area that substantially corresponds to or is provided at the transition portion between the C-pillar portion and the rocker portion. The overlapping area between the C-pillar and the B-pillar is interpreted as an overlapping area that substantially corresponds to or is provided at the transition portion between the C-pillar portion and the B-pillar portion. The overlapping area between the C-pillar and the A-pillar is interpreted as an overlapping area that substantially corresponds to or is provided at the transition portion between the C-pillar portion and the A-pillar portion. The overlapping area for the B-pillar is interpreted as the overlapping area formed within the B-pillar section. The overlapping area for the A-pillar is interpreted as the overlapping area formed within the A-pillar section. The overlapping area for the C-pillar is interpreted as the overlapping area formed within the C-pillar section.

[0060] In this invention, the length of the overlapping area is interpreted as the distance along the longitudinal axis of a beam portion that is part of the overlapping area, such as an A-pillar portion or a rocker portion. The longitudinal axis of a beam portion that is part of the overlapping area may correspond to the longitudinal axis of the vehicle, i.e., the axis extending from the rear to the front. The height of the overlapping area is interpreted as the distance along the longitudinal axis of a front or rear pillar portion that is part of the overlapping area, which is substantially perpendicular to the length of the overlapping area, such as the longitudinal axis of a B-pillar portion, a hinge pillar portion, or a C-pillar portion. The height of the overlapping area may substantially correspond to the vertical axis of the vehicle, i.e., the axis extending from the floor to the roof. The length and / or height of the overlapping area may vary along the overlapping area.

[0061] The overlap area between the B-pillar and the rocker may have a length (distance along the longitudinal axis of the rocker) of 20 to 600 mm, preferably 100 to 500 mm, and more preferably 200 to 400 mm. The height (distance along the longitudinal axis of the B-pillar) may also be 20 to 600 mm, preferably 100 to 500 mm, and more preferably 200 to 400 mm. The overlap areas between the C-pillar and the rocker, the overlap area between the hinge and the rocker, and the overlap area between the A-pillar and the B-pillar may be similar in size to the overlap area between the B-pillar and the rocker.

[0062] The length of the overlapping area between the A-pillar and the hinge (the distance along the longitudinal axis of the A-pillar) may be 20 to 600 mm, preferably 40 to 400 mm. The height (the distance along the longitudinal axis of the hinge-pillar) may be 20 to 600 mm, preferably 40 to 300 mm. The length (the distance along the longitudinal axis of the A-pillar) and height (the distance along the longitudinal axis of the hinge-pillar) of the overlapping area between the C-pillar and the A-pillar may be the same as the length and height of the overlapping area between the A-pillar and the hinge.

[0063] The overlapping area of ​​the A-pillar may have a length (distance along the longitudinal axis of the A-pillar portion) of 20 to 600 mm, preferably 40 to 400 mm, and a height (distance perpendicular to the length) of 20 to 600 mm, preferably 40 to 400 mm.

[0064] The overlapping area of ​​the B-pillar may have a height (distance along the longitudinal axis of the B-pillar portion) of 20 to 600 mm, preferably 40 to 300 mm, and a length (distance perpendicular to the longitudinal axis of the B-pillar portion) of 20 to 400 mm, preferably 40 to 200 mm.

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

[0066] The integral bodyside structural frame is formed by joining a plurality of blanks, where at least two blanks are joined together by one of the overlapping areas, so that the integral bodyside structural frame comprises at least two blanks, for example, four blanks.

[0067] In some embodiments, each section may include multiple blanks, for example, a B-pillar section may be formed from two or three blanks.

[0068] The unitary bodyside structural frame may include a joint between at least two blanks with an overlapping area. The overlapping joint between the two blanks may be welded by spot welding or other welding or joining techniques. Welding two blanks in an overlapping area to form the unitary bodyside structural frame may improve the productivity of the welding process. Therefore, when the blanks are not welded through the overlapping area, for example, in a butt joint weld configuration, dimensional gaps between the blanks may be prevented. Therefore, the overlapping joint may help accommodate different tolerances of the blanks.

[0069] In some embodiments, the one-piece body side structural frame may include a joint between two blanks having an overlapping area and another joint having an end-to-end configuration, for example, a square butt joint.

[0070] In some embodiments, transforming the composite blank to form the integral body side structural frame comprises hot forming the composite blank. At least a portion of the blank may be formed from an ultra-high strength steel (UHSS). Boron steel, such as 22MnB5 or other steel compositions mentioned above, may be a suitable UHSS. These blanks, such as boron steel blanks, may include an aluminum silicon coating or a zinc coating.

[0071] In some embodiments, hot forming may comprise heating the composite blank above the austenitizing temperature, cooling the composite blank to a temperature of, for example, 400-600°C, and forming the composite blank to form a one-piece bodyside structural frame. In some embodiments, this forming may comprise multiple forming steps. These forming steps may comprise, for example, forming, trimming, or cutting, and may occur in a single multi-stage press. Examples of forming comprising multiple forming steps may be found in U.S. Patent No. 9,492,859 and WO 2016142367.

[0072] Alternatively, the composite blank may be deformed by cold forming. High strength or ultra high strength steel may be used to form a one-piece body side structural frame by cold forming.

[0073] The blanks forming the composite may be of different materials and / or thicknesses. For example, Usibor® (e.g., Usibor® 1500 or Usibor® 2000) blanks and Ductibor® (e.g., Ductibor® 500 or Ductibor® 1000) blanks or portions of blanks may be used. The use of these types of materials in the hot-forming process results in a predominantly martensitic structure in the Usibor® portion and a predominantly ferritic-pearlitic structure in the Ductibor® portion. According to these aspects, the properties of the integral bodyside structural frame can be tailored.

[0074] According to another aspect, there is provided a one-piece body side structural frame obtainable by the method according to any of the examples herein.

[0075] In some embodiments, the integral body side structural frame may include regions having different tensile strengths as described in any embodiment herein. In some of these embodiments, the regions having different tensile strengths may have different microstructures.

[0076] In some embodiments, at least one of the blanks may have regions with different tensile strengths. The blank may be made of two different materials with different tensile strengths. The region with the lower tensile strength may have appropriately higher ductility, thereby increasing energy absorption during a crash.

[0077] Alternatively, these regions having different tensile strengths may have different microstructures. Different microstructures can be formed in a hot-formed integral bodyside structural frame. These microstructures can be formed by heating the composite blank above the austenitizing temperature and controlling the cooling of the composite blank during forming to form the bodyside structural frame. The cooling of different regions of the composite blank can be controlled by providing areas of the forming tool with heaters. Thus, the integral bodyside structural frame comprises areas having a predominantly martensitic structure and areas having ferrite, pearlite, bainite, or combinations thereof. Alternatively, different microstructures can be formed by locally heating a portion of the integral bodyside structural frame, for example, with laser light. The integral bodyside structural frame is press-hardened to transform the predominantly martensitic structure into a structure including ferrite, and / or pearlite, and / or bainite, and / or tempered martensite, and combinations thereof. The tensile strength of the predominantly martensitic structure may be greater than 1400 MPa, preferably greater than 1500 MPa. On the other hand, the region having a lower strength may have a tensile strength of 1000 MPa, preferably less than 800 MPa, for example 500 to 800 MPa. [Brief explanation of the drawings]

[0078] Non-limiting examples of the present invention will now be described with reference to the accompanying drawings. [Figure 1] FIG. 1 shows an example of a one-piece body side structural frame for a vehicle, as described in the prior art. [Figure 2]FIG. 2 shows a cross-sectional view of the integral body side structural frame of FIG. 1 taken along line A-A'. [Figure 3] FIG. 3 shows an embodiment of a one-piece body side structural frame for a vehicle. [Figure 4] FIG. 4 shows a cross-sectional view of the integral body side structural frame of FIG. 3 taken along line A-A'. [Figure 5] FIG. 5 shows the composite blank before it is deformed to form the one-piece body side structural frame of FIG. [Figure 6A] FIG. 6A shows another embodiment of a one-piece body side structural frame for a vehicle. [Figure 6B] FIG. 6B shows another embodiment of a one-piece body side structural frame for a vehicle. [Figure 7] FIG. 7 shows another embodiment of a one-piece body side structural frame for a vehicle. [Figure 8A] FIG. 8A shows an embodiment of a one-piece body side structural frame joined to an A-pillar plate and rocker plate. [Figure 8B] FIG. 8B shows an embodiment of a one-piece body side structural frame joined to the A-pillar plate and rocker plate. [Figure 9] FIG. 9 shows another embodiment of a one-piece body side structural frame for a vehicle. [Figure 10] FIG. 10 shows another embodiment of a one-piece body side structural frame for a vehicle. [Figure 11] FIG. 11 shows another embodiment of a one-piece body side structural frame for a vehicle. DETAILED DESCRIPTION OF THE INVENTION

[0079] In these figures, the same reference numerals are used to indicate corresponding elements.

[0080] 1 shows an example of a vehicle integral body side structural frame 1 described in the prior art. The body side structural frame 1 includes a rocker section 3, an A-pillar section 5, a hinge pillar section 4 connecting the rocker section 3 to the A-pillar section 5, and a B-pillar section 2 connecting the rocker section 3 to the A-pillar section 5. The hinge pillar section 4 is located at the front of the vehicle, while the B-pillar is located at the center with respect to the longitudinal axis of the vehicle.

[0081] The bodyside structural frame 1 is formed from two blanks, a first blank 10 and a second blank 20. The blanks are joined together by welding along a laser weld line 19. The blanks are welded "end to end," for example with a square butt joint. The blanks are first welded to form a composite blank. This composite blank is then deformed to form the one-piece bodyside structural frame 1. Thus, the first blank 10 and the second blank 20 are pre-assembled and simultaneously deformed in a composite forming process.

[0082] Although not shown in Figure 1, it can be seen that the integral body side structural frame 1 is joined to the remaining portions of the vehicle's structural skeleton. In Figure 1, the rocker section 3 is joined to the inner plate of the vehicle's rocker (not shown in Figure 1), and the A-pillar section 5 is joined to the inner plate of the vehicle's A-pillar (not shown in Figure 1).

[0083] 2 shows a cross-sectional view of the one-piece bodyside structural frame 1 of FIG. 1 along line A-A', including the rocker and A-pillar inner plates. The one-piece bodyside structural frame 1 is joined to the A-pillar inner plate 70 and the rocker inner plate 60.

[0084] The A-pillar inner plate 70 includes a lower flange 71 and an upper flange 72. The integral bodyside structural frame, particularly the A-pillar section 5, is connected to the A-pillar inner plate 70 via the upper flange 72. As mentioned above, the A-pillar lower flange 71 does not perfectly match the A-pillar section 5 of the bodyside structural frame 1. That is, a gap exists between the lower flange 71 and the bodyside structural frame 1. Such a gap may represent a weakness in terms of structural behavior during a collision.

[0085] Rocker inner plate 60 includes a lower flange 61 and an upper flange 62. The bodyside structural frame is connected to rocker inner plate 60 via lower flange 61. Similar to the connection of A-pillar inner plate 70 to A-pillar section 5, rocker inner plate 60 does not perfectly mate with rocker section 3 of bodyside structural frame 1, and this gap may be a structural weakness.

[0086] The one-piece body side structural frame blanks of Figures 1 and 2 are welded end-to-end and do not form overlapping areas.

[0087] FIG. 3 shows an embodiment of an integral body side structural frame 1 for a vehicle. In this embodiment, the body side structural frame 1 in FIG. 3 is a front frame. The body side structural frame has an integral structure. The lower beam section includes a rocker section 3. The upper beam section includes an A-pillar section 5. The front beam section includes a hinge pillar section 4 connecting the rocker section 3 to the A-pillar section 5. The rear beam section includes a B-pillar section 2 connecting the rocker section 3 to the A-pillar section 5. The B-pillar section may include a U-shaped section with two horizontal flanges.

[0088] The one-piece bodyside structural frame 1 of FIG. 3 is formed from two blanks, a first blank 10 and a second blank 20, which are joined together to form a composite blank. The composite blank is deformed to form the one-piece bodyside structural frame 1. The first blank 10 and the second blank partially overlap in an overlap area 11, i.e., only a portion of the first blank overlaps a portion of the second blank.

[0089] In the embodiment of FIG. 3 , the first blank 10 and the second blank 20 are spot welded via an overlap area 11. In this particular embodiment, the overlap area 11 is located at the bottom of the first blank 10. The top of the first blank 10 is laser welded to the second blank 20 via a laser weld seam 19. Laser welding the top of the first blank 10 to the second blank 20 may include removing the coating from the blank or using powder or wire to reduce the effect of the coating. Other methods for reducing the adverse effects of the coating may be used for joints without overlap, such as oscillating a laser beam acting on the weld area or applying a magnetic field to the weld area to mix the coating with the base material of the blank.

[0090] In this embodiment, a given blank, i.e., first blank 10, may include at least a portion of the B-pillar section 2. Another blank may include the remaining portion of the body side structural frame. For example, second blank 20 may include at least a portion of the rocker section 3, hinge section 4, and A-pillar section 5. Thus, the first blank, which substantially corresponds to the B-pillar, may have a substantially elongated shape. Such a shape may help optimize material usage in the coil for forming the blank and minimize waste.

[0091] In this embodiment, the overlap area 11 may be formed substantially at the transition between the rocker portion 3 and the B-pillar portion 2. This overlap area may be referred to as the B-pillar and rocker overlap area 11.

[0092] In other embodiments, one or more overlapping areas may additionally or alternatively be formed in other portions of the integral body side structural frame.

[0093] FIG. 4 shows a cross-sectional view of the one-piece bodyside structural frame 1 of FIG. 3 taken along line A-A'. The bodyside structural frame 1 is joined to the A-pillar inner plate 70 and the rocker inner plate 60. The bodyside structural frame is connected to the rocker inner plate 60 via a lower flange 61. As the thickness of the bodyside structural frame in the overlap region 11 increases, the overlap region 11 can provide sufficient rigidity to the one-piece bodyside structural frame to at least mitigate adverse structural effects of the one-piece bodyside structural frame not perfectly matching the rocker inner plate 60 and the rocker portion 3 of the bodyside structural frame 1.

[0094] FIG. 5 shows the composite blank 100 before it is deformed to form the bodyside structural frame of FIG. 3. The composite blank 100 is formed by joining two blanks, a first blank 10 and a second blank 20. The first blank 10 and the second blank 20 partially overlap at an overlap area 11. In this example, the top of the first blank 10 is laser welded end-to-end to the second blank 20 via a weld line 19. Once the blanks are joined together, the composite blank 100 is formed. This composite blank is then deformed to form the one-piece bodyside structural frame as shown in FIG. 3.

[0095] Deforming may involve hot forming, i.e., optionally heating the composite blank in a furnace above an austenitizing temperature, particularly Ac3. After heating in the furnace, the blank may be transferred to a press and deformed therein to obtain the final shape of the bodyside structural frame. During and immediately after forming, quenching may occur. In particular, quenching may involve cooling greater than the critical cooling rate to obtain a martensitic microstructure. In some embodiments, quenching may be avoided in selected portions of the bodyside structural frame.

[0096] FIG. 6A shows another embodiment of a vehicle integral body side structural frame 1. The integral body side structural frame 1 of FIG. 6A is a front frame formed from four blanks. Each blank may include at least a portion of an A-pillar portion 5, a B-pillar portion 2, a hinge pillar portion 4, and a rocker portion 3. For example, a first blank 10 may be joined to a second blank 20 and a third blank 30. Meanwhile, a fourth blank 40 may be joined to the second blank 20 and the third blank 30 on the opposite side. In FIG. 6A , the first blank 10 may include at least a portion of the complete 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 a portion of the A-pillar portion, or in some cases the complete A-pillar portion. The fourth blank 40 may include at least a portion of the hinge pillar portion 4.

[0097] In these embodiments, the one-piece body side structural frame may include multiple overlap areas. For example, a predetermined overlap area 11 is provided corresponding to the transition between the rocker portion 3 and the B-pillar portion 2. The overlap area may be referred to as a B-pillar-rocker overlap area 11. The one-piece body side structural frame may also include an A-pillar-hinge pillar overlap area 13. This A-pillar-hinge pillar overlap area 13 is provided corresponding to the transition between the A-pillar and the hinge pillar.

[0098] Blanks that are joined via overlapping areas can be spot welded. Other blanks that are joined without overlapping areas between them can be welded to each other along weld lines 19.

[0099] The overlap area 11 between the B-pillar and the rocker may have a length (distance along the longitudinal axis of the rocker) equal to the width of the B-pillar section, i.e., the width from one lateral flange to another lateral flange, and a height (distance along the longitudinal axis of the B-pillar) equal to the height of the rocker section 3, i.e., the height from the lower flange to the upper flange of the rocker section. In other embodiments, the height of the overlap area 11 between the B-pillar and the rocker may be less than the height of the rocker section.

[0100] The overlap area 13 between the A-pillar and the hinge may have the same length as the width of the hinge pillar portion.

[0101] In some embodiments, the area extending from the hinge pillar to the A-pillar may experience significant loads during a collision. Increasing the thickness from the third overlapping area increases the stiffness of the area.

[0102] FIG. 6B shows another embodiment of a one-piece body-side structural frame 1 for a vehicle similar to the embodiment shown in FIG. 6A. The body-side structural frame 1 of FIG. 6B includes a first blank 10 having a B-pillar portion 2 and is joined to a second blank 20 in a B-pillar and rocker overlap region 11 and to a third blank 30 in an A-pillar and B-pillar overlap region 12. In this figure, the second blank 20 includes a rocker portion 3 and is joined to a fourth blank 40 via a hinge and rocker overlap region 14. The fourth blank 40 may include a hinge portion 4 and may be joined to the third blank in an A-pillar and hinge overlap region 13. In this embodiment, the third blank 30 includes a portion of the A-pillar portion 5. Thus, in FIG. 6B, the one-piece body-side structural frame 1 is formed from four blanks.

[0103] In another embodiment, the integral body side structural frame may be formed from additional blanks that may be joined between or to any of the blanks by overlapping areas or end-to-end welds.

[0104] Figure 7 shows another embodiment of a vehicle one-piece body side structural frame 1 similar to the embodiment shown in Figures 6A and 6B. In Figure 7, the body side structural frame 1 has an overlapping area 11 between the B-pillar and rocker where the first blank 10 and the second blank 20 partially overlap, and an overlapping area 12 between the A-pillar and the B-pillar where the first blank 10 and the third blank 30 partially overlap.

[0105] 7, the overlapping area 11 between the B-pillar and the rocker has a length corresponding to the width of the B-pillar portion 2 at the bottom and a height corresponding to half the height of the rocker portion 3. According to this embodiment, the first blank 10 does not completely cover the height of the rocker portion 3. Similarly, the overlapping area 12 between the A-pillar and the B-pillar may have a length corresponding to the width of the B-pillar portion 2 at the top and a height corresponding to half the height of the A-pillar portion 5. In other embodiments, the shape of the overlapping area depends on the shape of the body side structural frame and / or the structural behavior of the vehicle.

[0106] In these examples, the fourth blank 4 is welded to the third blank 3 and the second blank 5 along weld line 19. Alternatively, the joints may be formed by partially overlapping the blanks described in any of the examples herein.

[0107] The integral body side structural frame may have regions with different mechanical properties to control deformation of the integral body side structural frame or increase the energy absorbed by the body side structural frame in a collision while at least maintaining the overall strength of the body side structural frame.

[0108] The integral bodyside structural frame 1 of FIG. 7 can be deformed by hot forming and hardened. The integral bodyside structural frame of FIG. 7 is formed from four blanks of boron steel with an aluminum-silicon coating. After press hardening, the bodyside structural frame has a predominantly substantially martensitic microstructure with a tensile strength greater than 1400 MPa. Meanwhile, the first blank 10 of the bodyside structural frame has a region 25 with a lower tensile strength. The region 25 with a lower tensile strength has a different microstructure relative to the martensitic structure. Such a lower strength region 25 may comprise ferrite, bainite, pearlite, tempered martensite, and / or combinations thereof. Thus, the tensile strength of the lower strength region may be less than 1000 MPa. Therefore, the ductility of this region is increased. Energy absorption may also be increased. Furthermore, deformation of the bodyside structural frame can be more precisely controlled. Thus, the integral body side structural frame may have regions with tensile strengths greater than 1400 MPa, i.e., a hard range, and regions with tensile strengths less than 1000 MPa, i.e., a soft range.

[0109] In FIG. 7, the area of ​​lower strength 25 may be formed in the lower portion of the first blank 10, directly above the overlap area 11 between the B-pillar and the rocker. According to this embodiment, the overlap area 11 between the B-pillar and the rocker may correspond to the lowest region of the B-pillar section 2. As a result, the overlap area 11 between the B-pillar and the rocker, i.e., the area where the first blank and the second blank partially overlap, provides rigidity to the body side structural frame. The area of ​​lower strength 25 also helps control deformation of the B-pillar section so that intrusion of this section may be reduced during a collision.

[0110] The regions 25 having lower strength may be formed by differential cooling of these regions of the composite blank while it is pressed in the press tool during the hot-forming die-quenching process to form the bodyside structural frame. Alternatively, such regions may be formed by differential heating during hot-forming to prevent these regions from reaching temperatures higher than the austenitizing temperature. In another example, lower strength may be achieved by locally heating some regions of the integral bodyside structural frame after press hardening to modify the microstructure in those regions.

[0111] In other embodiments, the lower strength region may be formed from a material having different mechanical properties relative to the remainder of the bodyside structural frame rather than modifying the microstructure to change the mechanical properties, e.g., tensile strength and elongation. For example, the lower strength region 25 may be formed from Ductibor®, and the remainder of the bodyside structural frame may be formed from Usibor®.

[0112] In other embodiments, the blanks may have different thicknesses. In other embodiments, some blanks may be comprised of portions having different thicknesses.

[0113] In any of the embodiments disclosed herein, the integral body side structural frame includes "patchwork," ie, localized reinforcements applied to the composite blank.

[0114] It should be noted that these different methods for improving the response of the integral bodyside structural frame during a crash may be incorporated into the bodyside structural frame and at least one blank.

[0115] The integral body side structural frame according to other embodiments may have areas of lesser strength to improve the frame during a crash according to any of the embodiments described with respect to FIG.

[0116] While in the above-described embodiment, the one-piece bodyside structural frame is joined to the lower flange of the rocker inner plate and the upper flange of the A-pillar inner plate, it may alternatively be joined to the rocker outer plate and / or the A-pillar outer plate. In some cases, the vehicle framework may include the rocker or A-pillar outer or inner plates, e.g., for manufacturing purposes, prior to joining the bodyside structural frame. Figures 8A and 8B show an embodiment of a one-piece bodyside structural frame joined to the A-pillar plate and the rocker plate.

[0117] In Figure 8A, the lower portion of the integral body side structural frame 1 is joined to the lower flange of the inner plate of the rocker 60. In this embodiment, the second blank 20 is joined to the lower flange 61 of the inner plate of the rocker 60 in the same manner as in Figure 4. The third blank 30 may be joined to the upper flange 77 of the outer plate 75 of the A-pillar.

[0118] 8B, the second blank 20 is joined to the lower flange 66 of the outer plate of the rocker 65, while the third blank 30 is joined to the upper flange 72 of the inner plate of the A-pillar 70 in the same manner as in FIG.

[0119] FIG. 9 shows another embodiment of an integrated body side structural frame 1 for a vehicle. This integrated body side structural frame is a rear frame. In this embodiment, the lower beam section may include a rocker section 3. The front pillar section may include a B-pillar section 2. The rear pillar section and the upper beam section may include a C-pillar section 6 extending from the rocker section 3 toward the B-pillar section 2.

[0120] The integral body side structural frame 1 has one or more overlapping areas. In this figure, the structural frame 1 has a B-pillar and rocker overlapping area 11 and a C-pillar and B-pillar overlapping area 16. The structural frame 1 in this figure has three blanks. One blank 10 includes the B-pillar portion 2. Another blank 20 includes the rocker portion 3. Another blank 50 includes the C-pillar portion 6. In this embodiment, the blanks 10 and 50 partially overlap in the C-pillar and B-pillar overlapping area 16. The blanks 10 and 20 partially overlap in the B-pillar and rocker overlapping area 11. Meanwhile, the blanks 20 and 50 are joined end to end via a weld line 19.

[0121] In other embodiments, the structural frame 1 may only have one of the B-pillar and rocker overlap area 11 and the C-pillar and B-pillar overlap area 16 .

[0122] Alternatively, or additionally, one of the overlapping areas may substantially correspond to a transition between the C-pillar portion and the rocker portion, i.e., the structural frame may comprise an overlapping area between the C-pillar and the rocker.

[0123] FIG. 10 shows another embodiment of a vehicle integral body side structural frame 1. This integral body side structural frame surrounds a single opening for the vehicle's front and rear doors. In this embodiment, the lower beam section may include a rocker section 3. The front pillar section may include a hinge pillar section 4. The rear pillar section may include a C-pillar section 6. The upper beam section may include an A-pillar section 5. The A-pillar section 5 may extend from the hinge section 4 toward the C-pillar section 6. The C-pillar section 6 may extend from the rocker section 3 toward the A-pillar section 5.

[0124] In this figure, the one-piece body side structural frame 1 has a predetermined overlap area 17 formed in the A-pillar section 2. Therefore, the A-pillar section 2 can be formed by partially overlapping blanks 31 and 32. Connections between other blanks can be formed via weld lines 19 between the ends.

[0125] In other embodiments, one or more overlapping areas may be formed in other portions of the integral body side structural frame 1 .

[0126] In some embodiments, the structural frame 1 may include an A-pillar / hinge overlap area that substantially corresponds to the transition between the A-pillar portion and the hinge pillar portion.

[0127] Alternatively, or additionally, one of the overlapping areas may substantially correspond to a transition between the C-pillar portion and the rocker portion, i.e., the structural frame may comprise an overlapping area between the C-pillar and the rocker.

[0128] Alternatively, or additionally, one of the overlapping areas may substantially correspond to the transition between the hinge portion and the rocker portion, i.e. the structural frame may comprise an overlapping area of ​​the hinge and the rocker.

[0129] In these embodiments, the integral bodyside structural frame 1 does not include thirteen pillar sections, whereas the B-pillars may be formed separately and joined to the integral bodyside structural frame to form a "non-integral" bodyside structural frame.

[0130] In another aspect, a method for manufacturing a bodyside structural frame formed from a B-pillar joined to a one-piece bodyside structural frame is provided. The method includes providing a one-piece bodyside structural frame to enclose both a front door opening and a rear door opening that do not include a B-pillar portion as described in any embodiment herein, providing a B-pillar, and joining the B-pillar to the one-piece bodyside structural frame. As a result, a "non-one-piece" bodyside structural frame can be manufactured.

[0131] 11 shows another embodiment of a vehicle integral bodyside structural frame 1, as well as an integral bodyside structural frame with a B-pillar section 2. In this embodiment, a blank including the B-pillar section is joined to another blank before being deformed, e.g., hot formed. The B-pillar section 2 may be formed between a hinge pillar 4 and a C-pillar section 6 and extend from a rocker section 3 toward an A-pillar section 5.

[0132] As shown in FIG. 10, in addition to the A-pillar overlap area 17, the integral body side structural frame 1 may also include a B-pillar and rocker overlap area 11 and an A-pillar and B-pillar overlap area 12.

[0133] The integral body side structural frame 1 may comprise any combination of one or more of the overlapping areas described with respect to FIG.

[0134] In another aspect, a method for manufacturing a bodyside structural frame formed from two integral bodyside structural frames is provided. The method includes providing a integral front bodyside structural frame according to any embodiment disclosed herein, providing a integral rear bodyside structural frame according to any embodiment disclosed herein, and joining the front bodyside structural frame and the rear bodyside structural frame along a B-pillar portion to form the bodyside structural frame. Thus, the resulting structural frame is a "non-integral" bodyside structural frame.

[0135] For completeness, various aspects of the invention are set out in the following numbered clauses.

[0136] [Section 1] 1. A method for manufacturing a one-piece body side structural frame for a vehicle, comprising: The method comprises: providing a plurality of blanks; and joining the blanks together to form a composite blank; the step of joining the blanks includes partially overlapping two blanks to form one or more overlapping areas; the method comprising deforming the composite blank to form the unitary body side structural frame; The integral body side structural frame is Lower beam section, Upper beam section, a front pillar portion connecting the lower beam portion to the upper beam portion; and a rear pillar section connecting the lower beam section to the upper beam section.

[0137] [Section 2] The step of joining the blanks together comprises: welding the blanks together in one or more of the overlapping areas; 2. A method for manufacturing an integral body side structural frame according to claim 1, comprising spot welding the blank in particular in at least one of the overlapping areas.

[0138] [Section 3] 3. The method for manufacturing an integral body side structural frame of claim 1, wherein at least one of the overlapping areas substantially corresponds to a transition between a beam portion and a pillar portion.

[0139] [Section 4] A method for manufacturing an integrated body side structural frame as described in any one of paragraphs 1 to 3, wherein at least one of the overlapping areas is formed within a beam portion and / or a pillar portion.

[0140] [Section 5] 5. The method for manufacturing an integral body side structural frame described in any one of claims 1 to 4, wherein the step of deforming the composite blank to form the integral body side structural frame comprises hot forming the composite blank.

[0141] [Section 6] 6. The method for manufacturing an integral body side structural frame according to any one of claims 1 to 5, wherein the plurality of blanks are made of different materials and / or thicknesses.

[0142] [Section 7] 7. The method for manufacturing an integral body side structural frame according to any one of claims 1 to 6, wherein the integral body side structural frame comprises a portion of an outer frame.

[0143] [Section 8] 8. The method for manufacturing a one-piece body side structural frame as recited in claim 7, wherein the one-piece body side structural frame is an outer frame.

[0144] [Section 9] 8. The method for manufacturing an integral body side structural frame according to any one of claims 1 to 7, wherein the integral body side structural frame comprises a portion of an inner frame.

[0145] [Section 10] 10. The method for manufacturing a one-piece body side structural frame as recited in claim 9, wherein the one-piece body side structural frame is an inner frame.

[0146] [Section 11] 7. The method for manufacturing an integral body side structural frame according to any one of claims 1 to 6, wherein the integral body side structural frame comprises a portion of an outer frame and a portion of an inner frame.

[0147] [Section 12] The integral body side structural frame is a front frame, the lower beam portion includes a rocker portion; the upper beam portion comprises an A-pillar portion; the front pillar portion includes a hinge pillar portion, 12. The method for manufacturing an integral body side structure frame according to any one of claims 1 to 11, wherein the rear pillar portion comprises a B-pillar portion.

[0148] [Section 13] 13. The method for manufacturing a one-piece body side structural frame as recited in claim 12, wherein one of the overlapping areas substantially corresponds to a transition between the rocker section and the B-pillar section.

[0149] [Section 14] 14. A method for manufacturing an integral body side structural frame as described in either paragraph 12 or paragraph 13, wherein one of the overlapping areas substantially corresponds to a transition between the B-pillar portion and the A-pillar portion.

[0150] [Section 15] A method for manufacturing an integral body side structural frame as described in any one of paragraphs 12 to 14, wherein one of the overlapping areas substantially corresponds to the transition between the A-pillar portion and the hinge pillar portion.

[0151] [Section 16] A method for manufacturing an integral body side structural frame as described in any one of paragraphs 12 to 15, wherein one of the overlapping areas substantially corresponds to the transition portion between the rocker portion and the hinge pillar portion.

[0152] [Section 17] 17. The method for manufacturing an integral body side structural frame according to any one of claims 12 to 16, wherein one of the overlapping areas is formed within an A-pillar portion.

[0153] [Section 18] The integral body side structural frame is a rear frame, the lower beam portion includes a rocker portion; the front pillar portion includes a B-pillar portion, A method for manufacturing an integrated body side structure frame as described in any one of paragraphs 1 to 11, wherein the upper beam portion and the rear pillar portion include a C-pillar portion extending from the rocker portion toward the B-pillar portion.

[0154] [Section 19] 20. The method for manufacturing a one-piece body side structural frame as described in paragraph 18, wherein one of the overlapping areas substantially corresponds to a transition between the rocker section and the B-pillar section.

[0155] [Section 20] 20. A method for manufacturing an integral body side structural frame as described in either paragraph 18 or paragraph 19, wherein one of the overlapping areas substantially corresponds to a transition between the B-pillar portion and the C-pillar portion.

[0156] [Section 21] A method for manufacturing an integral body side structural frame as described in any one of paragraphs 18 to 20, wherein one of the overlapping areas substantially corresponds to a transition portion between the C-pillar portion and the rocker portion.

[0157] [Section 22] the lower beam portion includes a rocker portion; the front pillar portion includes a hinge pillar portion, the rear pillar portion includes a C-pillar portion, the upper beam portion comprises an A-pillar portion; The A-pillar portion extends from the hinge pillar portion toward the C-pillar portion, 12. The method for manufacturing an integrated body side structure frame according to any one of claims 1 to 11, wherein the C-pillar portion extends from the rocker portion toward the A-pillar portion.

[0158] [Section 23] 23. A method for manufacturing an integral body side structural frame as set forth in any of paragraphs 22, wherein one of the overlapping areas corresponds substantially to the transition between the A-pillar portion and the hinge pillar portion.

[0159] [Section 24] 24. A method for manufacturing an integral body side structural frame as described in either paragraph 22 or paragraph 23, wherein one of the overlapping areas substantially corresponds to a transition between the rocker section and the C-pillar section.

[0160] [Section 25] A method for manufacturing an integral body side structural frame as described in any one of paragraphs 22 to 24, wherein one of the overlapping areas substantially corresponds to the transition between the rocker section and the hinge pillar section.

[0161] [Section 26] A method for manufacturing an integral body side structural frame as described in any one of paragraphs 22 to 25, wherein one of the overlapping areas substantially corresponds to the transition between the A-pillar portion and the C-pillar portion.

[0162] [Section 27] 27. The method for manufacturing an integral body side structural frame according to any one of claims 22 to 26, wherein one of the overlapping areas is formed within an A-pillar portion.

[0163] [Section 28] A method for manufacturing an integral body side structural frame as described in any one of paragraphs 22 to 27, wherein the integral body side structural frame also includes a B-pillar portion formed between the hinge pillar portion and the C-pillar portion and extending from the rocker portion toward the A-pillar portion.

[0164] [Section 29] 28. A method for manufacturing a one-piece body side structural frame as described in paragraph 27, wherein one of the overlapping areas substantially corresponds to a transition between the rocker section and the B-pillar section.

[0165] [Section 30] 30. A method for manufacturing an integral body side structural frame as described in either paragraph 28 or paragraph 29, wherein one of the overlapping areas substantially corresponds to a transition between the B-pillar portion and the A-pillar portion.

[0166] [Section 31] 31. An integral body side structural frame as obtained by the method according to any one of paragraphs 1 to 30.

[0167] [Section 32] the integral body side structural frame includes regions having different tensile strengths; 32. The integral body side structural frame of claim 31, wherein the regions having different tensile strengths have different microstructures.

[0168] [Section 33] 1. A method for manufacturing a body side structural frame, comprising: a step of providing an integrated front body side structure frame according to any one of paragraphs 12 to 17; providing an integrated rear body side structure frame according to any one of paragraphs 18 to 21; and joining the integral front body side structural frame and the integral rear body side structural frame along the B-pillar portion to form a body side structural frame.

[0169] [Section 34] 1. A method for manufacturing a body side structural frame, comprising: providing an integrated body side structure frame according to any one of paragraphs 22 to 27; providing a B-pillar; and joining the B-pillar to the integral body side structural frame.

[0170] [Section 35] 1. A method for manufacturing a body side structural frame, comprising: providing an outer integral body side structural frame as set forth in paragraph 8; providing an inner integral body side structural frame as set forth in paragraph 10; and joining the outer integral body side structural frame and the inner integral body side structural frame together to form a body side structural frame.

[0171] While numerous embodiments are disclosed herein, other alternatives, modifications, uses, and / or equivalents of these embodiments may exist. Also, all possible combinations of the described embodiments are covered. Accordingly, the scope of the present invention should not be limited to any particular embodiment, but should instead be determined by a fair interpretation of the following claims.

Claims

1. 1. A method for manufacturing a one-piece body side structural frame for a vehicle, comprising: The method comprises: providing a plurality of blanks; and joining the blanks together to form a composite blank; the step of joining the blanks includes partially overlapping two blanks to form one or more overlapping areas; the method comprising deforming the composite blank to form the unitary body side structural frame; The integral body side structural frame is Lower beam section, Upper beam section, a front pillar portion connecting the lower beam portion to the upper beam portion; and a rear pillar section connecting the lower beam section to the upper beam section.

2. The step of joining the blanks together comprises: welding the blanks together in one or more of the overlapping areas; 2. A method for manufacturing an integral body side structural frame according to claim 1, comprising spot welding said blanks together, in particular in at least one of said overlapping areas.

3. The method for manufacturing an integral body side structural frame according to any one of claims 1 to 2, wherein at least one of said overlapping areas substantially corresponds to a transition between a beam portion and a pillar portion.

4. The method for manufacturing an integral body side structural frame according to any one of claims 1 to 3, wherein at least one of the overlapping areas is formed in a beam section and / or a pillar section.

5. The integral body side structural frame is a front frame, the lower beam portion includes a rocker portion; the upper beam section comprises an A-pillar section; the front pillar portion includes a hinge pillar portion, The method for manufacturing an integral body side structural frame according to any of claims 1 to 4, wherein the rear pillar portion comprises a B-pillar portion.

6. 6. The method for manufacturing a one-piece body side structural frame as set forth in claim 5, wherein one of said overlapping areas corresponds substantially to a transition between said rocker section and said B-pillar section.

7. 7. A method for manufacturing an integral body side structural frame according to any one of claims 5 to 6, wherein one of said overlapping areas corresponds substantially to a transition between said B-pillar portion and said A-pillar portion.

8. A method for manufacturing an integral body side structural frame according to any one of claims 5 to 7, wherein one of said overlapping areas corresponds substantially to a transition between said A-pillar portion and said hinge pillar portion.

9. A method for manufacturing an integral body side structural frame according to any one of claims 5 to 8, wherein one of the overlapping areas corresponds substantially to a transition between the rocker section and the hinge pillar section.

10. The integral body side structural frame is a rear frame, the lower beam portion includes a rocker portion; the front pillar portion includes a B-pillar portion, The method for manufacturing an integral body side structural frame according to any one of claims 1 to 4, wherein the upper beam portion and the rear pillar portion comprise a C-pillar portion extending from the rocker portion toward the B-pillar portion.

11. the lower beam portion includes a rocker portion; the front pillar portion includes a hinge pillar portion, the rear pillar portion includes a C-pillar portion, the upper beam section comprises an A-pillar section; The A-pillar portion extends from the hinge pillar portion toward the C-pillar portion, The method for manufacturing an integral body side structural frame according to any one of claims 1 to 4, wherein the C-pillar portion extends from the rocker portion towards the A-pillar portion.

12. 12. A method for manufacturing a one-piece bodyside structural frame as claimed in any preceding claim, wherein the step of deforming the composite blank to form the one-piece bodyside structural frame comprises hot forming the composite blank.

13. A method for manufacturing an integral body side structural frame according to any preceding claim, wherein a plurality of said blanks are of different materials and / or different thicknesses.

14. An integral bodyside structural frame as obtained by the method according to any one of claims 1 to 13.

15. the integral body side structural frame includes regions having different tensile strengths; 15. The one-piece body side structural frame of claim 14, wherein the regions having different tensile strengths have different microstructures.

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