Closed Structural Member Press Forming Latch Flange
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Solution Overview
Problem
The weight of closed structure parts increases with the number of sub-parts, and existing manufacturing methods require multiple steps and sub-parts, leading to inefficiencies and higher costs.
Innovation Solution
A press forming method that processes a metal blank into a closed structure part with a latch flange portion, allowing two joint ends to be fixed together using a press forming die, reducing the number of sub-parts and manufacturing steps by forming a latch flange portion that overlaps and latches the other joint end, while simultaneously shaping the outer portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple press sub-parts are used to form a closed structure part, then the closed structure part can be assembled from separate components, but the weight of the closed structure part increases due to additional flange portions
Solution Approach 1:
The patent merges multiple press sub-parts into a single integrated blank, eliminating the need for separate flange portions and connection elements. The closed structure part is formed from one continuous metal blank, which reduces overall weight while maintaining structural integrity and assembly capability.
Solution Approach 2:
The patent segments the forming process into distinct stages: pre-forming the blank into an interim part with closed section, then closing the structure by forming the latch flange portion, and finally press-joining to complete the closed structure. This segmentation allows complex geometry to be achieved from a single blank without requiring multiple separate components.
2Ease of manufacture
If multiple press sub-parts are used to form a closed structure part, then the structure can be assembled from separate components, but the number of manufacturing steps increases
Solution Approach 1:
The patent combines multiple manufacturing operations into a single integrated press forming process. The pre-forming, closing, and press-joining steps are performed sequentially in one manufacturing cycle, eliminating the need for separate assembly operations and reducing total manufacturing time.
Solution Approach 2:
The patent performs preliminary pre-forming of the blank into an interim part with the closed section geometry before the final closing operation. This preliminary shaping prepares the material for the subsequent latch flange formation and press-joining, enabling the entire closed structure to be created in one continuous process rather than requiring multiple discrete steps.
3Ease of manufacture
If multiple press sub-parts are used to form a closed structure part, then the structure can be assembled from separate components, but the manufacturing cost increases
Solution Approach 1:
The patent merges multiple components into a single blank, eliminating costs associated with producing, inventorying, and assembling multiple separate parts. The integrated forming process reduces material waste, simplifies tooling requirements, and eliminates secondary assembly operations, thereby reducing overall manufacturing cost.
Solution Approach 2:
The patent discards the traditional approach of using multiple separate press sub-parts with individual flange portions. By recovering and utilizing a single continuous blank throughout the forming process, the patent eliminates redundant material and manufacturing steps, reducing both material costs and processing costs.
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 method reduces the number of sub-parts and manufacturing steps, resulting in a lighter and more efficiently produced closed structure part with reduced weight and manufacturing costs.
Implementation Method 1
pressing the blank using a press forming die so as to form one joint end of the blank into a latch flange portion
Data Source
Figure 1(A)~1(B)
Figure 2
Figure 3
AI summary
A method for reducing the number of sub-parts of a closed structure part and the number of steps for manufacturing the closed structure part is provided and, therefore, the closed structure part is efficiently manufactured. In the method for manufacturing closed structure parts, a punch 84 is moved in the pressing direction. A joint end 19, which is one of two joint ends of a blank 24, is bent using a pressing force exerted by a flange processing portion 102. The joint end 19 overlaps a joint end 21, which is the other joint end of the blank 24. The joint end 19 is made into a latch flange portion 20 for latching the joint end 21. At the same time, the blank 24 is pressed by using two press forming surfaces 96 and 97, and two shoulder portions 26 of the blank 24 are press-formed into predetermined shapes. In this way, the joint end 19 is made into the latch flange portion 20. The latch flange portion 20 latches the other joint end 21, and the latch flange portion 20 can be fixed to the joint end 21. Simultaneously, the two shoulder portions 26 can be press-formed into predetermined shapes.