Vehicle Body Side Frame Overlap Layout for Crash Strength
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Solution Overview
Problem
The existing methods for manufacturing body side structural frames for vehicles face challenges such as reduced mechanical properties due to aluminum-silicon coatings in welding, additional processing steps required for coating removal, and incomplete closure of sections like the A-pillar and rocker, leading to potential strength reductions during crashes.
Innovation Solution
A method involving the formation of a unitary body side structural frame by joining blanks with overlapping regions to increase thickness and strength, eliminating the need for coating removal and additional materials, while maintaining precise material arrangement for weight reduction and improved structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aluminum-silicon coating is applied to steel blanks for corrosion protection, then corrosion resistance is improved, but mechanical properties are reduced due to coating interference during welding
Solution Approach 1:
The patent removes the aluminum-silicon coating from the steel blanks before welding to eliminate the harmful effect of the coating on mechanical properties. By extracting the problematic coating layer, the welding process can proceed without coating interference, preserving the strength and mechanical properties of the welded joints while maintaining corrosion protection through alternative means or post-weld treatment.
2Strength
If coating removal is performed to maintain mechanical properties, then strength is improved, but additional processing steps are required
Solution Approach 1:
The patent performs coating removal as a preliminary action before welding, integrating it into the manufacturing flow. By removing the coating in advance rather than dealing with it during or after welding, the process eliminates the need for complex in-process coating management or post-weld remediation steps, streamlining the overall manufacturing process while ensuring optimal mechanical properties.
3Ease of manufacture
If sections like A-pillar and rocker are not completely closed, then manufacturing is simplified, but strength is reduced during crashes
Solution Approach 1:
The patent applies local quality by providing different structural characteristics in different regions of the body side structural frame. Specifically, critical sections such as the A-pillar and rocker are designed with complete closure and enhanced thickness to maximize strength where needed for crash performance, while other non-critical areas may maintain simpler, lighter constructions. This localized reinforcement ensures optimal crash strength without unnecessarily complicating the entire structure.
4Strength
If blanks are joined with overlapping regions, then thickness and strength are increased, but weight increases
Solution Approach 1:
The patent applies local quality by implementing overlapping regions only in specific, critical areas of the body side structural frame where enhanced strength and thickness are required for safety and structural integrity. Rather than uniformly overlapping all blanks throughout the structure, the design strategically places overlaps at high-stress zones, maintaining minimal weight while achieving necessary strength enhancements where they provide the most benefit.
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 enhances the structural strength and stiffness of the vehicle's body side frame by increasing thickness in critical areas, reducing weight, and eliminating the need for additional processing steps, thereby improving crash performance and manufacturing efficiency.
Implementation Method 1
joining the blanks to each other to form a composite blank
Implementation Method 2
shaping the composite blank, e.g. by hot forming or cold forming
Data Source
AI summary
A method for manufacturing a unitary body side structural frame for a vehicle is provided. The method comprises providing a plurality of blanks, joining the blanks to each other to form a composite blank wherein joining the blanks includes forming one or more overlapping regions formed by partially overlapping two blanks and deforming the composite blank to form the unitary body side structural frame. A unitary body side structural frame as obtained by any of the methods herein described is also provided.