Extruded Vehicle Body Component with Non-Coplanar Axes
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Solution Overview
Problem
Current methods for manufacturing vehicle body components, such as hydroforming and welding of stamped or roll-formed pieces, are limited by material thickness and require additional manufacturing steps, which can compromise strength and efficiency.
Innovation Solution
The method involves extruding an elongate member with a longitudinally extending cross-section and bending it using a multi-axis bending machine about non-parallel axes to form complex vehicle body components, such as roof rails and A-pillars, eliminating the need for multiple pieces and welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hydroforming or welding of stamped/roll-formed pieces is used to manufacture vehicle body components, then the desired cross-sectional strength can be achieved, but the manufacturing process becomes complex and is limited to lower gauge thickness materials
Solution Approach 1:
The patent combines multiple manufacturing operations (extrusion, bending, forming) into a single integrated process that produces complex 3D vehicle body components from flat sheet material in one continuous operation, eliminating the need for separate stamping, forming, and welding steps while maintaining structural strength
Solution Approach 2:
The patent replaces traditional mechanical welding and assembly processes with a unified forming process that creates monolithic 3D structures through controlled material deformation, eliminating weld joints and assembly steps while achieving equivalent or superior structural integrity
2Shape
If multiple stamped or roll-formed pieces are welded together to form vehicle body components, then complex cross-sections can be achieved, but additional manufacturing steps are required which reduce efficiency
Solution Approach 1:
The patent merges multiple discrete manufacturing steps (cutting, bending, forming, welding) into a single continuous process that transforms flat sheet material directly into complex 3D components, eliminating intermediate steps and significantly improving manufacturing throughput
Solution Approach 2:
The patent performs preliminary material preparation and forming operations in a single integrated sequence before final component completion, allowing complex geometries to be achieved through pre-planned material deformation paths that eliminate subsequent assembly operations
3Quantity of substance
If traditional manufacturing methods are used for vehicle body components, then material thickness is limited to lower gauge, but the structural integrity may be compromised
Solution Approach 1:
The patent changes the geometric parameters of the extruded profile to include closed sections and optimized wall thickness distributions that provide high structural strength while using thinner gauge materials, achieving better strength-to-weight ratios than traditional methods
Solution Approach 2:
The patent employs extruded profiles with composite cross-sectional geometries that combine different wall thicknesses and material distributions within a single component, allowing thin-walled sections to achieve the structural performance of thicker materials through optimized geometry
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 allows for the creation of strong, unitary vehicle body components with reduced material usage and manufacturing steps, enhancing structural integrity and efficiency while accommodating complex geometries.
Implementation Method 1
extruding an elongate member that has a longitudinally extending cross section
Implementation Method 2
bending the elongate member with multi-axis bending machine about a first axis and subsequently about second axis non-parallel to the first axis
Data Source
AI summary
A vehicle body component is provided. The vehicle body component includes an extruded elongate member that has a longitudinally extending cross section. The elongate member includes a first section that extends along a first axis, a second section that extends from the first section along a second axis, and a third section that extends from the second section along a third axis, wherein the first axis and the third axis are non-coplanar with respect to each other.