Multi-Layer Flat Steel Product for Optimized Crash Safety

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Solution Overview

Problem

Existing methods for producing automotive components fail to simultaneously achieve lightweight construction and meet safety requirements in crash scenarios while accommodating varying material properties across different sections of a component, necessitating a solution that optimizes material properties in all directions of a flat steel product.

Innovation Solution

A multi-layer flat steel product with alternating high-strength and low-strength steel alloy layers, where the high-strength steel has a carbon content of 0.2-0.5% and the low-strength steel has a carbon content up to 0.15%, allowing for tailored material properties through hot forming and press hardening, enabling components with varying strengths and bending angles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If single-material construction is used, then manufacturing simplicity is maintained, but inability to meet locally varying strength requirements worsens

Engineering Contradiction:

Improvelocal material property variationVSAvoidmaterial structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The steel flat product is divided into multiple layers with different steel grades (e.g., high-strength steel layers and lower-strength steel layers), allowing each layer to be optimized for specific local requirements while maintaining a manageable layered structure

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different layers of the steel flat product are assigned different material properties (strength, ductility, carbon content) to match the specific functional requirements of different component sections, enabling high-strength materials to be used only where necessary

Inventive Principle:

Principle #3Local quality

2Strength

If high-strength steel is used throughout, then crash safety is improved, but vehicle weight increases

Engineering Contradiction:

Improvecrash safetyVSAvoidvehicle weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

High-strength steel layers are strategically positioned only in regions requiring enhanced crash safety (such as outer layers or specific zones), while lower-strength steel layers are used in non-critical areas, optimizing the strength-to-weight ratio

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The steel flat product functions as a composite material system combining multiple steel grades in a layered structure, leveraging the advantages of each material type to achieve overall safety performance while minimizing weight

Inventive Principle:

Principle #40Composite materials

3Weight of moving object

If sheet thickness is reduced for lightweight construction, then vehicle weight decreases, but component strength is compromised

Engineering Contradiction:

Improvevehicle weightVSAvoidcomponent strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The multi-layer steel flat product acts as a composite material where high-strength steel layers compensate for reduced overall thickness, maintaining component strength while enabling lighter weight construction

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Instead of increasing thickness to achieve strength, the solution transitions to a multi-dimensional layered structure with varying material properties through the thickness direction, achieving strength through material composition rather than geometric dimension

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

The solution enables the production of components with locally optimized material properties in all directions, enhancing crash performance and reducing weight, thereby meeting safety and lightweight construction demands.

Implementation Method 1

consisting of a plurality of steel alloy layers joined together by hot rolling

Methodology Applied

Scientific EffectHot rolling:

Data Source

PatentEP3200950B1Multilayered flat steel product and component produced therefrom

Publication Date: 2019.12.25 THYSSENKRUPP STEEL EUROPE AG PATENTE PATENT DEPARTMENT

Figure 1a~1b
Figure 1c~1d
Figure 2a

AI summary

The invention relates to a multi-layer flat steel product (1) consisting of a plurality of steel alloy layers (2, 3a, 3b, 4a, 4b) connected to one another, wherein in at least one of the steel alloy layers (2, 3a, 3b, 4a, 4b) a steel of a first steel alloy is provided and in at least one other of the steel alloy layers (2, 3a, 3b, 4a, 4b) a steel of a second steel alloy, which is different from the first steel alloy, is provided, wherein the steel of the first steel alloy is a steel of high strength and the steel of the second steel alloy is a steel of lower strength and contains a lower proportion of carbon. In order to allow functionally optimized modelling of local material properties in all directions, the invention proposes that at least within one layer (plane of the metal sheet) at least one steel of the first steel alloy and at least one steel of the second steel alloy are provided. The invention also relates to a component (5), in particular for a vehicle body, consisting of a corresponding flat steel product (1).