Masked Heating Station for Precise Soft-Hard Zone Forming

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Solution Overview

Problem

Existing technologies for creating tailored material properties in press hardened parts, such as tailored rolled blanks, tailored welded blanks, and tailored heating, face issues like high tooling costs, process control challenges, part distortion, and limited ability to create precise soft/hard zones, especially in smaller areas.

Innovation Solution

A heating station with lower and upper masks that control radiation heating by blocking or allowing it to specific portions of a metal sheet blank, using support projections and movable masks to create precise heating patterns, enabling localized soft and hard zones in press hardened components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If tailored rolled blanks or tailored welded blanks are used to create soft/hard zones, then material properties can be differentiated in large areas, but tooling costs increase and process control becomes more difficult

Engineering Contradiction:

Improvematerial property differentiationVSAvoidtooling complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The heating process is segmented into different zones using masks with specific opening patterns. The lower mask and upper mask divide the heating chamber into regions that receive different amounts of thermal energy, creating localized soft and hard zones without requiring complex tailored blanking tools

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Masks are introduced as intermediary elements between the heating source and the metal blank. These masks selectively block or transmit thermal radiation to achieve the desired material property distribution, avoiding direct complex tooling contact with the blank

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If tailored tempering is used in the tool, then soft/had zones can be created, but part distortion increases and tool wear increases

Engineering Contradiction:

Improvematerial property differentiationVSAvoidpart distortion

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The heating process is performed as a preliminary action before forming. By creating the desired material property distribution in the blank beforehand through selective heating, subsequent forming operations can proceed without inducing additional distortion from tool-based tempering

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The mechanical contact-based tailored tempering process is replaced with a thermal radiation-based heating process. This substitution eliminates the need for mechanical tool-blank contact, thereby reducing tool wear and minimizing part distortion

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Area of stationary object

If existing tailored heating technology is used, then large areas of parts can be heated, but transition zones become large and reproducibility decreases

Engineering Contradiction:

Improveheating areaVSAvoidheating zone precision

Core Design Contradiction:

Area of stationary objectVSManufacturing precision

Solution Approach 1:

The heating area is segmented into precisely controlled zones using masks with specific opening patterns. The lower mask and upper mask work together to define exact heating regions, enabling both large area coverage and sharp transition zones with high reproducibility

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heating control is extended from a single-dimensional approach to a three-dimensional configuration using both lower and upper masks. This multi-dimensional arrangement allows precise control over heating patterns, creating well-defined transition zones while maintaining reproducibility

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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

Enables the production of structural car body components with customized crash path designs by allowing precise and controlled heating, reducing tooling costs and process complexity while maintaining part integrity.

Implementation Method 1

The heating elements may be configured to provide radiation heating towards the metal sheet blank

Methodology Applied

Scientific EffectRadiation heating: Thermal Radiation

Implementation Method 2

The lower mask may be adapted in shape and size to block the radiation heating from reaching at least a first portion of the metal sheet blank

Methodology Applied

Scientific EffectRadiation blocking: Absorption (EM radiation)

Data Source

PatentUS12435386B2Intermediate heating station with support projections on lower mask

Publication Date: 2025.10.07 AUTOMATION PRESS & TOOLING AP&T AB

AI summary

A heating station (1) for heating a metal sheet blank (50) and a system comprising such a heating station (1), is herein disclosed. In particular, the heating station comprises lower or upper heating elements (11) arranged in a heating chamber (10) below a metal sheet blank (50) when in a heating position, and configured to provide radiation heating towards the metal sheet blank (50), and a lower mask (14) arranged to block radiation heating from reaching at least a first portion of the metal sheet blank (50), wherein the lower mask (14) comprises a plurality of support projections (14d) projecting from a main surface (14a) of the lower mask (14) towards the metal sheet blank (50) when in a heating position, which support projections (14d) are configured to support a metal sheet blank (50) during heating thereof.