Hydroformed Tubular Pillar with Integrated Flange
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Solution Overview
Problem
Existing automotive structures for impact and structural components, such as roof rails and pillars, are inefficient in terms of manufacturing complexity and cost due to the need for multiple sheet metal stampings, which limits their formability and attachment to non-cylindrical cavities like vehicle pillars, and do not adequately meet the requirements for increased buckling strength during high-speed impacts.
Innovation Solution
A one-piece, tubular structural member with an integrated welded flange is created using roll-forming, extrusion, or hydroforming processes, which replaces multiple stamped components and can be curved or bent, providing a single-piece solution that integrates additional body panels and reduces manufacturing costs and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple sheet metal stampings are used to construct automotive structural components, then the components can be manufactured with traditional processes, but the manufacturing complexity increases and formability is limited
Solution Approach 1:
The patent combines multiple separate sheet metal stampings into a single integrated hydroformed component. The A-pillar assembly integrates the inner A-pillar panel, outer A-pillar panel, A-pillar reinforcement, and A-pillar extension into one monolithic tubular structure, eliminating the need for separate components and reducing assembly complexity.
Solution Approach 2:
The hydroformed tubular component serves multiple structural functions simultaneously. It provides the A-pillar framework, reinforcement, and panel attachment surfaces all within a single component, replacing what traditionally required multiple specialized parts.
2Adaptability or versatility
If traditional sheet metal stampings are used, then manufacturing is straightforward, but attachment to non-cylindrical cavities like vehicle pillars is limited
Solution Approach 1:
The patent utilizes hydroforming process parameters (high pressure fluid, temperature, timing) to transform a flat sheet metal blank into a complex three-dimensional tubular structure that conforms to the A-pillar cavity geometry. The process parameters enable the material to flow into and adapt to the non-cylindrical vehicle pillar cavity.
3Strength
If multiple components are assembled together, then structural strength can be achieved, but manufacturing costs and weight increase
Solution Approach 1:
The patent merges multiple structural elements into one integrated hydroformed component, eliminating the weight of additional fasteners, welds, and overlapping material from separate parts. The unified structure maintains structural integrity while reducing overall component weight.
4Strength
If traditional multi-piece construction is used, then manufacturing is conventional, but buckling strength during high-speed impacts is insufficient
Solution Approach 1:
The patent employs a single piece of high-strength steel material that is hydroformed into a complex tubular geometry. The material itself provides the necessary impact and buckling strength, while the hydroformed shape optimizes structural performance without requiring additional reinforcement layers or composite material combinations.
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 solution enhances structural integrity, reduces manufacturing complexity and costs, and meets higher impact strength standards by eliminating the need for additional reinforcement and complex operations, while allowing for more efficient packaging and styling flexibility.
Implementation Method 1
created according to any of a roll-forming, extrusion manufacturing, or hydroforming process
Implementation Method 2
a metal blank is heated to a temperature sufficient to austenize the metal and then quench hardened
Implementation Method 3
a metal blank is heated to a temperature sufficient to austenize the metal and then quench hardened
Implementation Method 4
heated to a temperature sufficient to austenize the metal and then quench hardened
Data Source
AI summary
A structural supporting roof pillar for use in a vehicle including an elongated, interiorly hollowed and polygonal shaped body having a selected arcuate lengthwise configuration and corresponding in placement to at least one of an A, B, and C vehicle pillar. A first component supporting flange is integrally formed, such as by overlapping end portions of a roll formed body, and projecting in at least a partially lengthwise extending fashion from a given cross sectional location. A secondary component supporting flange is affixed to a further cross sectional location associated with the body, such as further by welding.