Localized Pillar Reinforcement Blanks for Hot-Stamped Door Ring Parts
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Solution Overview
Problem
Current methods for producing reinforced automotive structural parts, such as the upper door ring, are inefficient due to the difficulty in manipulating small reinforcement elements during the hot stamping process and require different blanks for various vehicle models, leading to suboptimal production and adaptability.
Innovation Solution
Attaching reinforcement blanks to pillar parts before the hot stamping process, allowing them to be hot stamped together with pillar blanks, which are easier to handle, and modifying reinforcement properties by changing the blanks rather than the pillar blanks, enabling the use of the same pillar blanks for multiple vehicle models.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If small reinforcement elements are attached to pillar parts after hot stamping, then the reinforcement properties can be added to the structural part, but the manipulation of small reinforcement elements through stamping and attaching steps becomes difficult and production efficiency decreases
Solution Approach 1:
The patent merges the reinforcement element and the pillar blank into a single integrated blank before hot stamping. The reinforcement blank is attached to the pillar blank in advance, creating a combined blank that is then hot stamped together as one piece. This eliminates the separate manipulation and attaching steps for small reinforcement elements, thereby improving production efficiency while maintaining the reinforcement properties.
Solution Approach 2:
The patent applies preliminary action by attaching the reinforcement blank to the pillar blank before the hot stamping process. This pre-attachment allows the reinforcement element to be positioned and secured in advance, avoiding the difficulty of manipulating small elements during the stamping process and enabling more efficient production.
2Ease of manufacture
If a reinforced blank with localized thicker area is provided to directly shape the pillar, then the production process is simplified, but a different blank must be provided for each vehicle model depending on reinforcement requirements
Solution Approach 1:
The patent segments the pillar structure into a base pillar blank and separate reinforcement blanks. The reinforcement blanks can be independently designed and attached to the pillar blank according to different vehicle model requirements. This segmentation allows the same pillar blank to be used across multiple models by simply changing or adjusting the reinforcement blanks, thereby maintaining production simplicity while improving adaptability.
Solution Approach 2:
The patent applies local quality by providing reinforcement blanks with specific localized thicker areas only where needed for each vehicle model. Instead of creating entirely different blanks for each model, the reinforcement is applied locally to specific areas of a standardized pillar blank, maintaining ease of manufacture while adapting to different reinforcement requirements across vehicle models.
3Strength
If reinforcement elements are attached in the form of patches to center pillar and upper front pillar, then the pillars are reinforced to prevent bending in rollover accidents, but the small dimensions of reinforcement elements make manipulation through stamping and attaching steps difficult
Solution Approach 1:
The patent merges the reinforcement element and the pillar blank into a single integrated blank before hot stamping. The reinforcement blank is attached to the pillar blank in advance, creating a combined blank that is then hot stamped together as one piece. This eliminates the separate manipulation and attaching steps for small reinforcement elements, thereby improving production efficiency while maintaining the reinforcement properties.
Solution Approach 2:
The patent applies preliminary action by attaching the reinforcement blank to the pillar blank before the hot stamping process. This pre-attachment allows the reinforcement element to be positioned and secured in advance, avoiding the difficulty of manipulating small elements during the stamping process and enabling more efficient production.
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 method simplifies the production of reinforced structural parts, enhances adaptability across different vehicle models, and ensures robust mechanical properties to prevent roof crush in rollover accidents while maintaining a lightweight design.
Implementation Method 1
hot stamping the inner upper front pillar blank to form the inner upper front pillar, hot stamping the inner center pillar blank to form the inner center pillar, hot stamping the inner side rail blank to form the inner side rail
Data Source
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AI summary
Method for producing an inner automotive structural part comprising localized reinforced areas The method comprises the steps of: providing an inner upper front pillar blank (20), an inner center pillar blank (24) and an inner side rail blank, hot stamping the inner upper front pillar blank (20), hot stamping the inner center pillar blank (24), hot stamping the inner side rail blank, The method comprises, prior the hot stamping steps, the steps of: attaching an inner upper front pillar reinforcement blank (22) to a part of the inner upper front pillar blank (20), said inner upper front pillar reinforcement blank (22) being hot stamped together with the inner upper front pillar blank (20), attaching an inner center pillar reinforcement blank (26) to a part of the inner center pillar blank (24), said inner center pillar reinforcement blank (26) being hot stamped together with the inner center pillar blank (24).