Automobile Door Impact Member With Closed Sections and Fewer Parts

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Solution Overview

Problem

Existing impact-absorbing members for automobile doors require multiple components and complex manufacturing processes, leading to increased costs and potential welding-related issues, while achieving reduced panel rigidity and impact resistance with thinner steel sheets.

Innovation Solution

A single-piece impact-absorbing member for automobile doors with a connection band and interconnected portions, featuring a closed cross-sectional structure, is manufactured using a tailored or single-piece blank, integrated through welding without HAZ-softened portions, and formed via press-forming processes including hot stamping.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If multiple separate impact-absorbing members are used to achieve sufficient panel rigidity and impact resistance, then the mechanical performance is improved, but the number of components and manufacturing complexity increases

Engineering Contradiction:

Improvepanel rigidity and impact resistanceVSAvoidnumber of components and manufacturing process

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges multiple separate impact-absorbing members into a single integrated member with a complex three-dimensional structure. This single member includes multiple connected portions that can be attached to different locations on the exterior panel, combining the functions of multiple components into one piece that is formed and installed as a unit.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent employs a nested structure where multiple impact-absorbing portions are contained within or connected to a single integrated member. The member includes a main body with multiple connected portions that extend in different directions, creating a nested arrangement that provides multiple impact-absorbing functions within one component.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Strength

If separate impact-absorbing members are welded to the exterior panel one by one, then the impact resistance is improved, but the number of work steps and manufacturing costs increase

Engineering Contradiction:

Improveimpact resistanceVSAvoidmanufacturing efficiency and cost

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent combines multiple impact-absorbing members into one integrated component that can be attached to the exterior panel in a single operation. This eliminates the need for multiple separate welding operations, positioning steps, and quality checks that would be required if multiple separate members were installed individually.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent performs preliminary integration of multiple impact-absorbing portions into a single member during the manufacturing process. This preliminary action of combining components before installation reduces the complexity of the assembly process and minimizes the number of steps required during final installation on the vehicle.

Inventive Principle:

Principle #10Preliminary action

3Strength

If high strength steel sheets are applied to exterior panels, then the impact resistance is improved, but the sheet thickness must be increased which reduces weight reduction benefits

Engineering Contradiction:

Improveimpact resistanceVSAvoidexterior panel weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent employs a three-dimensional curved structure for the impact-absorbing member, utilizing complex spatial geometry rather than flat sheet configurations. This curved and volumetric structure provides enhanced mechanical strength and impact resistance while maintaining a compact form that does not require increased sheet thickness.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The patent uses a single integrated impact-absorbing member with a complex internal structure that combines multiple functional portions into one component. This composite-like structure provides enhanced strength-to-weight ratio compared to simple thick sheet steel, achieving impact resistance without proportionally increasing weight.

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

The solution provides excellent panel rigidity and impact resistance at lower costs by reducing component count and manufacturing steps, while maintaining weight reduction benefits of thinner steel sheets.

Implementation Method 1

heating the blank to a temperature in an austenite region and then rapidly cooling the blank during press-forming

Methodology Applied

Scientific EffectPhase transformation (austenite to martensite): Phase Change

Implementation Method 2

press-forming the heated blank to form the impact-absorbing member

Methodology Applied

Scientific EffectHot press-forming: Plasticity

Data Source

PatentUS20250303832A1Impact-absorbing member for automobile door, automobile door, blank, and method for manufacturing impact-absorbing member for automobile door

Publication Date: 2025.10.02 NIPPON STEEL CORPORATION

AI summary

This impact-absorbing member for an automobile door is an impact-absorbing member for an automobile door formed from a blank, which is a single-piece blank or a tailored blank, and includes: a connection band portion extending in a first direction; and at least three connected portions each having one end connected to the connection band portion and extending in a second direction intersecting the first direction, in which the connected portion has an impact-absorbing portion that is a closed cross-sectional structure.