Partial Press-Hardened Sheet Metal Component Thermal Shielding
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Solution Overview
Problem
Existing methods for producing partially press-hardened sheet metal components require high tooling effort and face challenges in process control, particularly in achieving localized hardness and strength variations.
Innovation Solution
A method involving partial heating of sheet metal components in an oven, where areas not to be hardened or hardened less are covered with rigid shell molds, allowing for thermal shielding and differential heating, followed by press hardening in a tool for defined cooling and hardening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If different areas of the sheet metal component are heated to different temperatures in the furnace to achieve varying hardness, then the manufacturing precision of localized hardness is improved, but the device complexity and tooling effort increase significantly
Solution Approach 1:
The patent introduces a covering device made of heat-insulating material as an intermediary between the furnace and the sheet metal component. This covering device selectively covers certain areas to prevent heating, thereby achieving localized hardness control without requiring complex multi-zone furnace systems or specialized tooling. The covering device acts as a simple yet effective mediator that transforms a complex thermal control problem into a straightforward covering/uncovering operation.
2Ease of operation
If the entire sheet metal component is heated uniformly in the furnace, then the process control is simplified, but the ability to achieve varying hardness in different areas is lost
Solution Approach 1:
The patent applies segmentation by dividing the sheet metal component into distinct areas that require different thermal treatments. The covering device is correspondingly segmented to cover only specific areas, allowing the uncovered areas to be heated uniformly while the covered areas remain at lower temperatures. This segmentation approach maintains simple overall process control while achieving precise localized hardness control.
3Manufacturing precision
If complex tooling is used to achieve partial press hardening with varying hardness, then the manufacturing precision of localized properties is improved, but the productivity and cost-effectiveness decrease
Solution Approach 1:
The patent changes the thermal parameters (temperature distribution) in the furnace by introducing a simple covering device rather than using complex tooling. This parameter change approach allows for partial press hardening with varying hardness properties while maintaining high productivity and cost-effectiveness. The covering device can be easily adjusted and removed, enabling flexible production without expensive specialized tooling.
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 reduces tooling requirements, allows for efficient production of components with varying hardness and strength, and can be easily integrated into existing press hardening systems, enabling cost-effective production of complex sheet metal components with tailored mechanical properties.
Implementation Method 1
at least one area of the shaped sheet metal part that is not to be hardened or hardened to a lesser extent is covered with two rigid shell molds... with the inner contour of the shell molds having the three-dimensional contour of the shaped sheet metal part in the area to be covered corresponds to or is approximated thereto
Implementation Method 2
the partially heated shaped sheet metal part is then press hardened... for partial heating in the furnace
Implementation Method 3
heated in an oven to the required hardening temperature
Implementation Method 4
the shaped sheet metal part partially covered in this way is brought into the oven as a whole... followed by press hardening
Implementation Method 5
subjected to different cooling in some areas in a press hardening tool
Data Source
Figure 1~2
Figure 3a~3b
Figure 4
AI summary
The method comprises transforming raw sheet metal material to a sheet metal mold part, pre-hardening the raw sheet metal material and heating the sheet metal mold part partially in a furnace in such a way that the area to be hardened is covered and is subjected to the press hardening. The non-covered area of the sheet metal mold part is heated in the furnace at above 900[deg] C. The mold formation of the sheet metal mold part corresponds to the vehicle body component. The raw sheet metal material is a coated steel plate. The method comprises transforming raw sheet metal material to a sheet metal mold part, pre-hardening the raw sheet metal material and heating the sheet metal mold part partially in a furnace in such a way that the area to be hardened is covered and is subjected to the press hardening. The non-covered area of the sheet metal mold part is heated in the furnace at above 900[deg] C. The mold formation of the sheet metal mold part corresponds to the vehicle body component. The raw sheet metal material is a coated steel plate. The degree of a thermal shielding of the relevant area is adjusted through the choice of the cover, a covering material, character of the covering material and/or arrangement on the sheet metal mold part. The covering is carried out by two shell molds that are arranged in relevant area on both sides at the sheet metal mold part. The shell mold is formed from a heat-resistant fiber material, a ceramic material, a metallic material or material composite. The shell mold is laid out not directly on the sheet metal mold part. Independent claims are included for: (1) a covering device; and (2) a vehicle body component.