Hot stamped class-a double door ring for vehicle

Abstract

Systems and methods for a hot stamped double door ring. An example double door ring has a class-A surface, the double door ring being formed from an inner portion and an outer portion, wherein the inner portion and outer portion are hot-stamped, and wherein the inner portion is a unitary piece of metal.

Description

HOT STAMPED CLASS-A DOUBLE DOOR RING FOR VEHICLE CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Prov. Patent App. No. 63 / 604049 titled, “HOT STAMPED CLASS-A DOUBLE DOOR RING FOR VEHICLE” and filed on November 29, 2023, the disclosure of which is hereby incorporated herein by reference in its entirety. BACKGROUND

[0002] Hot stamping is a technique which may be used to manufacture elements, such as metal portions which are used during vehicle manufacturing. SUMMARY

[0003] An example embodiment includes a double door ring having a class-A surface, the double door ring being formed from an inner portion and an outer portion, wherein the inner portion and outer portion are hot-stamped, and wherein the inner portion is a unitary piece of metal.

[0004] Another example embodiment includes a method for forming a double door ring for inclusion in a vehicle. The method includes milling individual portions of a die surface to cause local thinning of the portions, the portions being selected to correspond to portions of the double door ring which are associated with stretching or vertical portions; providing a blank to a press in an austenite state, wherein the press includes an upper die and a lower die, and wherein cooling channels of one or more of the upper die or the lower die are at least 10mm in diameter; forming a first part of the double door ring via hot stamping; and forming the double door ring from the first part and a second part.

[0005] Another example embodiment includes a method for forming a double door ring. The method includes milling individual portions of a die surface to cause local thinning of the portions, the portions being selected to correspond to portions of the double door ring which are associated with stretching or vertical portions; providing a blank to a press in an austenite state, wherein the press includes an upper die and a lower die, and wherein cooling channels of one or more of the upper die or the lower die are at least 10mm in diameter;forming, via the press, an inner double door via hot stamping; and forming the double door ring from the inner double door ring and an outer double door ring, wherein the inner double door ring and the outer double door ring have class-A surfaces. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The present disclosure is described with reference to the accompanying drawings, in which like reference characters reference like elements, and wherein:

[0007] Figure 1A illustrates a hot-stamped class-A inner portion and an outer portion of a double door ring for a vehicle.

[0008] Figure 1B illustrates a hot-stamped class-A double door ring formed from the portions.

[0009] Figure 2A illustrates detail of the outer portion of the double door ring.

[0010] Figure 2B illustrates detail of the inner portion of the double door ring.

[0011] Figures 3A-3E illustrate examples of dies and techniques used to form the double door ring described herein.

[0012] Figure 4 illustrates an example of the inner portion of the double door ring.

[0013] Figure 5 is a flowchart of an example process for forming a double door ring according to the techniques described herein. DETAILED DESCRIPTION

[0014] This application describes a double door ring formed from, in some embodiments, two hot stamped portions. The double door ring may be used as a bodyside of a vehicle, such as a track, car, and so on, with outer door connected to the bodyside. For example, the double door ring may encompass front and rear door rings which, in some embodiments, may connect to front and rear passenger doors. Thus, the double door ring may be a continuous part.

[0015] The use of hot stamping enables the manufacturing process of the vehicle to be simplified and faster. For example, in some embodiments the cycle time of the double door ring may be 10, 15, 20, 25, 30, 35, 40, 45, 50, 55 seconds, or less. A substantial number of multiple independent parts, each with different design requirements, may be removed and instead replaced with a single, unitary, piece (e.g., the outer or inner portion) as describedherein. Thus, the double door ring may represent a unitary double door ring formed from unitary pieces which post-stamping may, in some embodiments, be complete (e.g., be functional as a double door ring).

[0016] Additionally, the hot stamped portions may be A class portions (e.g., class- A surfaces). In some embodiments, the outer double door ring may have a class A surface. In this way, the hot stamped portions may be suitable for use in a consumer vehicle, such that they are suitable to being visible to persons when outer vehicle doors are opened. The double door ring may additionally provide interface surfaces for closure seals of the vehicle.

[0017] As known by those skilled in the art, hot stamping may include heating metal (e.g., high strength steel material) to a threshold temperature that converts it to an Austenite state (e.g., 900, 930, 950oC). The metal may then be stamped in a developed die for a desired shape. The metal may then be quenched (e.g., at substantially constant cooling speed) to achieve Martensite properties.

[0018] The double door ring described herein may act as a main structural component for the vehicle (e.g., front, side, roof, and rear crash). For example, the double door ring may be formed from one or more materials which have substantial strength. As an example, the materials may include a stainless-steel alloy, such as HF-950-1300-MnB-S and / or HF-800-950-MnB-S. The strength (e.g., tensile strength) may include any range between, for example, 750 and 1600 Mpa. For example, the strength may be a value between 750-900 Mpa, or 900-1150 Mpa, or 950-1250 Mpa, or 1300-1600 Mpa.

[0019] Example details related to HF-950-1300-MnB-S and / or HF-800-950-MnB- S, such as the composition are below with HF-800-950-MnB-S reflecting the top row and HF- 950-1300-MnB-S reflecting the bottom row.

[0020] In some embodiments, the hot stamped portions may be stamped using a manufacturing process as known by those skilled in the art. In some embodiments, the characteristics of the stamping process may be set or adjusted. For example, a die (e.g., an upper die, a lower die) may be used to stamp the inner portion or outer portion described herein.In this example, a blank formed from one or more materials may be used in combination with the die.

[0021] Figure 1A illustrates a hot-stamped class A outer portion 102 and an inner portion 104 of a double door ring for a vehicle. In some embodiments, only the outer portion 102 may have a class A surface. Figure 1B illustrates a hot-stamped class A double door ring 110 formed from the portions 102-104.

[0022] In some embodiments, the double door ring 110 may be formed via connecting the portions 102-104. For example, the portions 102-104 may be welded. As another example, the portions 102-104 may include elements associated with fastening. For this example, rivets, screws, and so on, may be used to connect the portions 102-104. As another example, epoxy may be used to form the double door ring 110. Additional techniques to connect, or otherwise join, the portions 102-104 may be used and fall within the scope of the disclosure.

[0023] Figure 2A illustrates details of the outer portion of the double door ring. The outer portion may, in some embodiments, be formed from two or more materials. For example, metal composition A may correspond, in some embodiments, to HF-800-950-MnB- S. As another example, metal composition B may correspond, in some embodiments, to HF- 950-1300-MnB-S.

[0024] The strength associated with HF-950-1300-MnB-S may be, in some embodiments, a tensile strength yield between about 900 and about 1150 Mpa and / or a tensile strength ultimate between about 1300 and about 1600 Mpa. The strength associated with HF- 800-950-MnB-S may be, in some embodiments, a tensile strength yield between about 750 and about 900 Mpa and a tensile strength ultimate between about 950 and about 1250 Mpa.

[0025] In some embodiments, a patch may be used to enhance, for example, strength at a particular portion of the outer portion. The patch may optionally be welded (e.g., spot welded, laser welded) onto a blank which is inserted into a die used to form the outer portion. In some embodiments, the patch may not be used, and the blank may be thicker at the particular portion.

[0026] The metal forming the outer portion may be of varying thickness. The thickness may be set based on, for example, desired functionality (e.g., crash characteristics, such as strength of the outer portion). For example, the portion on the left of the illustratedexample may be 1.6 mm.1.7 mm.1.8 mm.1.9 mm and so on. As another example, the portion on the right of the illustrated example may be 1.0 mm, 1.1 mm, 1.2 mm, 1.3 mm, and so on. The patch may be 1.6 mm.1.7 mm.1.8 mm.1.9 mm and so on. Thus, the location of the outer portion at the pitch may have thickness 2.6 mm, 2.7 mm, 2.8 mm, 2.9 mm, 3.0 mm, 3.1 mm, 3.2 mm, and so on.

[0027] Figure 2B illustrates details of the inner portion of the double door ring. The inner portion may, in some embodiments, be formed from one material. For example, the metal composition may be HF-950-1300-MnB-S. As another example, the metal composition may be HF-800-950-MnB-S. In some embodiments, the inner portion may be formed from two or more materials (e.g., similar to the outer portion).

[0028] The metal forming the inner portion may be of varying thickness. The thickness may be set based on, for example, desired functionality (e.g., crash characteristics, such as strength of the inner portion). For example, the portion on the left of the illustrated example may be 1.0 mm, 1.1 mm, 1.2 mm, 1.3 mm, and so on. As another example, the portion on the right of the illustrated example may be 2 mm, 2.1 mm. 2.2 mm. 2.3 mm, and so on.

[0029] Quenching optimization in the tools / dies may be performed. For example, ‘cooling surfaces’ may be optimized via thinning or surface compensation to avoid lack of quenching (e.g., gaps between forming steels). Additionally, in the tools / dies, ‘tangent to surface’ section(s) may be maintained as substantially homogeneous to keep an even temperature in the part. Examples of quenching and use of tools / dies is described in Figures 3A-3E.

[0030] Figures 3A-3E illustrate examples of dies and techniques used to form the double door ring described herein.

[0031] Figure 3A illustrates an example of a double door ring 302 (e.g., double door ring 102 or 104). In the illustrated embodiment, portion 304 is illustrated as having proper cooling with the portion 304 reflecting a flat surface where die contact is substantially direct. In contrast, portion 306 is illustrated as having material that stretches during forming. As a non-limiting example, the stretching may cause thinning of the material (e.g., the blank) which may may lead to gaps between the material and the die surface.

[0032] Thus, as described above different portions of the material of the ring 302 may cool differently. This may be based on material which stretches, material which hasvertical walls in the ring 302, and so on. In some embodiments, a die surface may be milled to ensure, or otherwise optimize, proper cooling of different areas of the double door ring 302. As an example, for portions of the material which are expected to stretch, the corresponding die surface may be milled (e.g., local thinning of the die surface, such as via .1, .2, and so on mm). Similarly, milling surfaces may be compensated considering reducing gaps in vertical walls. Thus, when forming the double door ring 302 the material may be more homogenously in contact with the die.

[0033] Figure 3B illustrates an example of cooling channel, such as channel 310. In some embodiments, the cooling channels may have a dimension of at least 10 mm in diameter. In some embodiments, the cooling channels may be 9 or 9.5 mm in diameter. In some embodiments the cooling channels may be a value within a range between, inclusively, 10 and 11mm in diameter. In some embodiments, the cooling channels within a die may have a same, or substantially same, diameter. As may be appreciated, the increased diameter as compared to dies known by those skilled in the art improves heat removal (e.g., via increased water flowing in the channels, such as channel 310). This may additionally enable shorter cooling times and faster production rates of double door rings (e.g., greater flexibility in cycle time). Additionally, the larger cooling channels may enhance quality due to enhanced cooling, such as leading to more consistent double door rings.

[0034] Figure 3C illustrates an example press (e.g., an upper ram, a lower bolster) along with two dies and associated cooling elements (e.g., coolant pipes, coolant channels connected to the pipes). The example press may use the enhanced cooling channels described in Figure 3B. Additionally, the upper die and / or lower die may have been milled as described in Figure 3A. The blank may be inserted into the press to form an inner or outer double door ring.

[0035] In some embodiments, the blanks described herein may have a length of about 2500, 2600, 2800, 3000 mm and a width of about 1500, 1600, 1700, 1800, 2000 mm. In some embodiments, the blank thickness may be between .8 and 3 mm.

[0036] Figure 3D illustrates an example of an upper die 320. As illustrated, the upper die includes cooling pipes 322 which feed into the die to cool the surface. The upper die 320 includes a surface 324 which is formed to correspond to a first surface of the doubledoor ring (e.g., a surface of an inner or outer double door ring). In the center there are holes which may correspond to the holes of the double door ring (e.g., the open spaces).

[0037] Figure 3E illustrates an example of a lower die 330. Similar to the above, the lower die includes cooling pipes or other elements associated with a cooling circuit. The lower die 330 additionally includes a surface that corresponds to a second surface of the double door ring (e.g., a surface of an inner or outer double door ring).

[0038] Figure 4 illustrates an example of the inner portion of the double door ring which has been hot-stamped.

[0039] Figure 5 is a flowchart of an example process for forming a double door ring. In some embodiments, the process may be performed by automatic techniques using automated robots. In some embodiments, persons may be involved in aspects of the process.

[0040] At block 502, a die (e.g., a die surface) is milled. As described above, the die may be milled (e.g., surfaces of the die milled) to thin, or otherwise adjust, the die to enhance cooling of the resulting part (e.g., double door ring). For example, portions which will be stretched may be milled (e.g., thinned). As another example, gaps in vertical walls may be reduced. For example, the geometry of the double door ring may require the material (e.g., the above-described metal or metals) to form steep or nearly vertical shapes. A gap may occur where contact isn’t optimal, or within a threshold, of a blank and the die surface. This gap may reduce the effectiveness of cooling. Thus, in some embodiments, portions of the die which may be associated with these gaps or vertical shapes may be thinned or otherwise adjusted. This may ensure better contact of the material with the die, such as during quenching.

[0041] At block 504, the blank is provided to a press (e.g., to an upper and lower die) in an Austenite state. As described above, the dies may have milled surfaced.

[0042] At block 506, an inner or outer double door ring is formed, for example via hot stamping as described herein. The press may form the blank into the inner or outer double door ring. As described above, the cooling channels of the dies may be increased in diameter as compared to current cooling channels.

[0043] At block 508, the inner / outer double door ring is combined. The process 502-506 may be repeated for the remaining double door ring (e.g., inner or outer portion), for example using a same press or a different press. The inner and outer portions may then be combined as described herein, for example via welding.Additional Embodiments

[0044] It is to be understood that not necessarily all objects or advantages may be achieved in accordance with any particular embodiment described herein. Thus, for example, those skilled in the art will recognize that certain embodiments may be configured to operate in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.

[0045] All of the processes described herein may be fully automated via software code modules, including one or more specific computer-executable instructions executed by a computing system. The computing system may include one or more computers or processors. The code modules may be stored in any type of non-transitory computer-readable medium or other computer storage device. Some or all the methods may be embodied in specialized computer hardware.

[0046] Many other variations than those described herein will be apparent from this disclosure. For example, depending on the embodiment, certain acts, events, or functions of any of the processes described herein can be performed in a different sequence, can be added, merged, or left out altogether (e.g., not all described acts or events are necessary for the practice of the processes). Moreover, in certain embodiments, acts or events can be performed concurrently, e.g., through multi-threaded processing, interrupt processing, or multiple processors or processor cores or on other parallel architectures, rather than sequentially. In addition, different tasks or processes can be performed by different machines and / or computing systems that can function together.

[0047] The various illustrative logical blocks and modules described in connection with the embodiments disclosed herein can be implemented or performed by a machine, such as a processing unit or processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A processor can be a microprocessor, but in the alternative, the processor can be a controller, microcontroller, or state machine, combinations of the same, or the like. A processor can include electricalcircuitry configured to process computer-executable instructions. In another embodiment, a processor includes an FPGA or other programmable device that performs logic operations without processing computer-executable instructions. A processor can also be implemented as a combination of external computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration. Although described herein primarily with respect to digital technology, a processor may also include primarily analog components. A computing environment can include any type of computer system, including, but not limited to, a computer system based on a microprocessor, a mainframe computer, a digital signal processor, a portable external computing device, a device controller, or a computational engine within an appliance, to be name a few.

[0048] Conditional language such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, are otherwise understood within the context as used in general to convey that certain embodiments include, while other embodiments do not include, certain features, elements and / or steps. Thus, such conditional language is not generally intended to imply that features, elements and / or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements and / or steps are included or are to be performed in any particular embodiment.

[0049] Disjunctive language such as the phrase “at least one of X, Y, or Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to present that an item, term, etc., may be either X, Y, or Z, or any combination thereof (e.g., X, Y, and / or Z). Thus, such disjunctive language is not generally intended to, and should not, imply that certain embodiments require at least one of X, at least one of Y, or at least one of Z to each be present.

[0050] Any process descriptions, elements or blocks in the flow diagrams described herein and / or depicted in the attached figures should be understood as potentially representing modules, segments, or portions of code that include one or more executable instructions for implementing specific logical functions or elements in the process. Alternate implementations are included within the scope of the embodiments described herein in which elements or functions may be deleted, executed out of order from that shown, or discussed,including substantially concurrently or in reverse order, depending on the functionality involved as would be understood by those skilled in the art.

[0051] Unless otherwise explicitly stated, articles such as “a” or “an” should generally be interpreted to include one or more described items. Accordingly, phrases such as “a device configured to” are intended to include one or more recited devices. Such one or more recited devices can also be collectively configured to carry out the stated recitations. For example, “a processor configured to carry out recitations A, B, and C” can include a first processor configured to carry out recitation A working in conjunction with a second processor configured to carry out recitations B and C.

Claims

WHAT IS CLAIMED IS:

1. A double door ring having a class-A surface, the double door ring being formed from an inner portion and an outer portion, wherein the inner portion and outer portion are hot- stamped, and wherein the inner portion is a unitary piece of metal.

2. The double door ring of claim 1, wherein the unitary piece of metal is formed from one type of metal.

3. The double door ring of claim 2, wherein the one type of metal is HF-950-1300- MnB-S.

4. The double door ring of claim 3, wherein the unitary piece of metal has varying thickness, and wherein a first portion of the unitary piece of metal has a thickness between 1 mm and 1.3 mm, and wherein a second portion of the unitary piece of metal has a thickness between 2 mm and 2.3 mm.

5. The double door ring of claim 1, wherein the outer portion is formed from two types of metal.

6. The double door ring of claim 5, wherein the two types of metal include HF-950- 1300-MnB-S and HF-800-950-MnB-S.

7. The double door ring of claim 6, wherein the outer portion has varying thickness, and wherein a first portion of the outer portion has a thickness between 1 mm and 1.3 mm, and wherein a second portion of the unitary piece of metal has a thickness between 1.6 mm and 1.9 mm.

8. The double door ring of claim 1, wherein a strength associated with at least a portion of the double door ring is between 750 and 900 Mpa.

9. The double door ring of claim 8, wherein the strength is a Rp0.2 yield strength.

10. The double door ring of claim 1, wherein a strength associated with at least a portion of the double door ring is between 950 and 1250 Mpa.

11. The double door ring of claim 10, wherein the strength is an Rm yield strength.

12. The double door ring of claim 1, wherein a strength associated with at least a portion of the double door ring is between 900 and 1150 Mpa.

13. The double door ring of claim 12, wherein the strength is a Rp0.2 yield strength.

14. The double door ring of claim 1, wherein a strength associated with at least a portion of the double door ring is between 1300 and 1600 Mpa.

15. The double door ring of claim 14, wherein the strength is an Rm yield strength.

16. A method for forming a double door ring for inclusion in a vehicle, the method comprising: milling individual portions of a die surface of an upper and / or lower die to cause local thinning of the portions, the portions being selected to correspond to portions of the double door ring which are associated with stretching or vertical portions; providing a blank to a press in an austenite state, wherein the press includes the upper die and the lower die, and wherein cooling channels of one or more of the upper die or the lower die are at least 10mm in diameter; forming a first part of the double door ring via hot stamping; and forming the double door ring from the first part and a second part.

17. The method of claim 16, wherein the first part is an outer double door ring.

18. The method of claim 16, wherein the second part is an inner double door ring.

19. The method of claim 16, wherein the blank is formed from HF-950-1300-MnB-S.

20. A method for forming the double door ring of claim 1, the method comprising: milling individual portions of a die surface of an upper and / or lower die to cause local thinning of the portions, the portions being selected to correspond to portions of the double door ring which are associated with stretching or vertical portions; providing the blank to a press in an austenite state, wherein the press includes the upper die and the lower die, and wherein cooling channels of one or more of the upper die or the lower die are at least 10mm in diameter; forming, via the press, an inner double door via hot stamping; and forming the double door ring from the inner double door ring and an outer double door ring, wherein the outer double door ring has a class-A surface.

21. The method of claim 20, wherein the inner double door ring is a unitary piece of metal.

22. The method of claim 20, wherein the outer portion is formed from two types of metal, and wherein the two types of metal include HF-950-1300-MnB-S and HF-800-950- MnB-S.

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