Recessed Reinforcing Pipe Profile for Two-Sided Body Shell Joining

Solution Overview

Problem

The existing methods for connecting reinforcing pipe profiles to unfinished motor vehicle body components, such as tailgates, are complex and costly due to the need for one-sided joining techniques, which limit accessibility and efficiency.

Innovation Solution

Incorporating recesses into the reinforcing pipe profiles allows for two-sided connections to unfinished shell parts, enabling the use of methods like spot-welding, riveting, or clinching, which are more accessible and cost-effective by allowing tools to reach the interior for connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If one-sided joining connections (laser welding, soldering, gluing) are used to connect reinforcing pipe profiles to unfinished shell parts, then the connection can be made with limited accessibility, but the production process becomes extremely complex and costly

Engineering Contradiction:

Improveproduction complexity and costVSAvoidaccessibility to connection points

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The reinforcing pipe profile is segmented by punching recesses at specific locations along its length. These recesses create accessible openings that allow joining tools to reach interior connection points from both sides of the pipe, transforming a one-sided connection problem into a two-sided connection solution. The pipe profile is effectively divided into accessible segments rather than treating it as a completely enclosed structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The recesses act as intermediary access points between the exterior environment and the interior connection points of the reinforcing pipe profile. By creating these intermediate openings, the invention enables standard two-sided joining tools to access otherwise inaccessible interior surfaces, allowing the use of simpler and more cost-effective joining methods.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If two-sided joining connections are used to connect reinforcing pipe profiles to unfinished shell parts, then the production process is simplified and becomes more cost-effective, but accessibility to the interior of the pipe profile is required

Engineering Contradiction:

Improveaccessibility to connection pointsVSAvoidstructure of reinforcing pipe profile

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The reinforcing pipe profile is segmented by punching recesses at specific locations along its length. These recesses create accessible openings that allow joining tools to reach interior connection points from both sides of the pipe, transforming a one-sided connection problem into a two-sided connection solution. The pipe profile is effectively divided into accessible segments rather than treating it as a completely enclosed structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The recesses are not distributed uniformly along the entire pipe profile but are strategically placed only at locations where connections to unfinished shell parts are required. This local modification approach maintains the structural integrity and closed-profile characteristics of the pipe in non-critical regions while providing accessibility only where needed for joining operations.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20250001845A1Unfinished Component for a Motor Vehicle Body

Publication Date: 2025.01.02 BAYERISCHE MOTOREN WERKE AG

AI summary

An unfinished component for a motor vehicle body has at least one first and one second unfinished shell part, which, in a box-like structural region, delimit a cavity in which is disposed a reinforcing pipe profile which is connected to at least one of the unfinished shell parts by a connection. In order to create an unfinished component which enables simpler and more cost-effective production, respective recesses are disposed in the reinforcing pipe profile. In the profile regions adjoining the recesses, the reinforcing pipe profile is connected to the associated unfinished shell part via respective connections on two sides. A method for producing an unfinished component of this type is also provided.