Vehicle Pillar Outer Panel Variable Thickness TRB Manufacturing
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Solution Overview
Problem
Existing vehicle center pillar outer panels manufactured using hot stamping or TRB methods face excessive deformation and fracture during side collisions due to inadequate energy absorption, particularly in transverse directions, which compromises passenger safety.
Innovation Solution
A vehicle outer panel with a variable transverse thickness structure is manufactured using a tailor rolled blank (TRB) method, where the side portions have reduced thicknesses compared to the central portion, allowing for energy absorption zones that absorb collision energy before fracture, utilizing an asymmetric rolling apparatus with rollers adjusted for length and thickness variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a panel is manufactured through hot stamping method to reduce weight while improving strength, then strength is improved, but deformation becomes excessive due to fracture during side collision
Solution Approach 1:
The patent applies local quality by creating a panel with non-uniform thickness distribution, where the thickness varies in the transverse direction to provide different mechanical properties in different regions. The thicker central portion provides strength while the thinner side portions allow controlled deformation for energy absorption during collisions.
2Weight of moving object
If TRB method is applied to manufacture panel with variable thickness, then weight is reduced and structural strength is improved, but energy absorption efficiency during collision is insufficient
Solution Approach 1:
The patent creates local quality variations in the panel thickness, specifically designing thinner side portions that can deform more easily during collision to absorb energy, while maintaining thicker central portions for structural strength. This local differentiation resolves the contradiction between weight reduction and energy absorption efficiency.
3Ease of manufacture
If uniform thickness structure is used, then manufacturing is simple, but collision energy cannot be absorbed effectively leading to fracture
Solution Approach 1:
The patent implements local quality by varying the panel thickness in the transverse direction, creating regions with different mechanical properties. This allows the panel to absorb collision energy effectively through controlled deformation in thinner regions while maintaining structural integrity in thicker regions, improving collision resistance without significantly complicating manufacturing.
4Strength
If thicker panel is used to prevent fracture, then strength is improved, but weight increases and energy absorption efficiency decreases
Solution Approach 1:
The patent applies local quality by creating a thickness gradient in the transverse direction, where the central portion is thicker for strength and the side portions are thinner for weight reduction and energy absorption. This localized thickness variation allows the panel to achieve both strength and weight efficiency without requiring uniform thickness throughout.
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 enhances energy absorption efficiency during collisions, reducing the risk of pillar fracture and improving passenger safety by distributing collision forces effectively across the panel, thereby minimizing damage and injury.
Implementation Method 1
a rolling step of TRB rolling a steel plate that is a material of an outer panel to generate a thickness change of the steel plate along a rolling direction
Data Source
AI summary
An outer panel for a pillar of a vehicle includes a central portion, flanges at opposite sides thereof for bonding to an inner panel, and opposite side portions between the central portion and the flange portions in a transverse sectional shape, wherein each of the side portions located at opposite sides of the central portion has a collision energy absorbing section having a thickness that is smaller than that of the central portion.