B-Pillar Hot-Shaping With Welded Overlap Blank

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Solution Overview

Problem

Existing methods for shaping sheetmetal blanks with reinforcing patches limit the flexibility in achieving different characteristics and hardness levels across various portions of a product, as they often require uniform steel grades and thicknesses, which restricts the design possibilities and increases material usage and costs.

Innovation Solution

The method involves combining two sheetmetal blank elements with an overlap, welding them together, and then shaping and hardening them simultaneously in a press-hardening process, allowing for different steel grades and thicknesses to create regions with varying strengths and corrosion protection, reducing material usage and costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If uniform steel grades and thicknesses are used throughout the blank, then manufacturing simplicity is maintained, but flexibility in achieving different characteristics and hardness levels across product portions is limited

Engineering Contradiction:

Improveflexibility in achieving different characteristicsVSAvoidcomplexity of blank construction

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The blank is divided into multiple blank elements (first blank element and second blank element) that can have different steel grades and thicknesses. These segmented elements are positioned relative to each other and welded to form a composite blank, enabling different portions of the final product to have different material properties while maintaining manufacturing flexibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses composite construction by combining different steel grades and thicknesses in various portions of the blank. The first and second blank elements are made of different steel grades and/or thicknesses, creating a composite structure that allows tailored mechanical properties, hardness levels, and corrosion resistance in different product regions.

Inventive Principle:

Principle #40Composite materials

2Strength

If reinforcing patches are added to sheetmetal blanks, then local strength enhancement is achieved, but material usage and costs increase

Engineering Contradiction:

Improvelocal strength enhancementVSAvoidmaterial usage

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

Instead of adding separate reinforcing patches, the invention segments the blank into multiple elements with different properties from the outset. The first and second blank elements have different steel grades and/or thicknesses, allowing strength enhancement in specific regions without adding extra material beyond what is already incorporated into the segmented structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention applies local quality by making different portions of the blank have different steel grades and thicknesses. This allows each region to have the specific material properties needed for its function, avoiding the need for additional reinforcing patches and reducing overall material usage while maintaining necessary strength characteristics.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If different steel grades and thicknesses are used in different blank portions, then tailored strength and corrosion properties are achieved, but manufacturing complexity increases

Engineering Contradiction:

Improvetailored strength and corrosion propertiesVSAvoidease of blank preparation

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The blank is segmented into first and second blank elements that can be prepared separately with different steel grades and thicknesses according to specific requirements. These segmented elements are then positioned relative to each other and welded together, enabling tailored material properties while maintaining a systematic manufacturing approach.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention employs composite materials by combining different steel grades and thicknesses in the blank structure. This allows each region to be optimized for its specific function (strength, corrosion resistance) while the composite nature is integrated into the blank design itself, streamlining the manufacturing process rather than adding complexity through separate reinforcement steps.

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enables the creation of products with tailored strength and corrosion properties across different portions, reducing material consumption and production costs while maintaining desired impact characteristics.

Implementation Method 1

The edges of the two blank elements are welded together

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 2

The blank is shaped in a tool

Methodology Applied

Scientific EffectPlasticity: Plasticity

Implementation Method 3

hardening a sheetmetal object in a cooled tool

Methodology Applied

Scientific EffectHardening: Heat Treatment

Data Source

PatentUS10155545B2Method of hot-shaping and hardening an object from a metal sheet, and a B-pillar for a vehicle

Publication Date: 2018.12.18 GESTAMP HARDTECH AB

AI summary

A B-pillar for a vehicle is made by the press hardening method. The blank is made by placing two blank elements (20,21) with an overlap (23) and welding the elements together before the shaping process.