Stepped Door Inner Panel Structure for Crack-Free Hot Stamping
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Solution Overview
Problem
Existing door inner panels require separate reinforcing members to achieve collision characteristics, leading to low manufacturing efficiency and high costs, and are prone to cracks and wrinkles due to their complex shape and low-strength steel material.
Innovation Solution
A panel-shaped formed product with a polygonal top panel portion, vertical wall portions extending from multiple borders, and step portions between adjacent vertical wall portions, produced using a method involving heating and hot stamping with a press working apparatus to enhance strength and reduce defects like cracks and wrinkles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a metal sheet with high workability is used to form a complex-shaped door inner panel, then the panel can be formed without cracks and wrinkles, but the strength and collision characteristics of the panel become insufficient
Solution Approach 1:
The patent merges the door inner panel and beltline reinforcement into a single integrated component formed from one metal sheet. The beltline reinforcement is formed as an integral part of the panel through press working, eliminating the need for separate reinforcing members while maintaining both forming quality and collision characteristics
Solution Approach 2:
The patent applies local quality by creating a beltline reinforcement portion with different structural characteristics from the main panel body. The reinforcement portion has increased thickness or structural complexity in specific areas to provide enhanced strength and collision resistance while the rest of the panel maintains its original forming characteristics
2Strength
If a separate beltline reinforcement is added to the door inner panel to improve collision characteristics, then the strength is enhanced, but the manufacturing efficiency decreases and production costs increase
Solution Approach 1:
The patent combines the door inner panel and beltline reinforcement into a single integrated component that is formed in one press working operation. This eliminates the need for separate manufacturing and assembly steps for the reinforcement, thereby improving manufacturing efficiency while maintaining enhanced collision characteristics
Solution Approach 2:
The metal sheet serves multiple functions: it forms both the main door inner panel and the beltline reinforcement portion. This multi-functionality eliminates the need for separate reinforcing members and reduces the number of components, improving productivity while maintaining structural integrity
3Strength
If a separate beltline reinforcement is added to the door inner panel to improve collision characteristics, then the strength is enhanced, but the device complexity and production costs increase
Solution Approach 1:
The patent merges the beltline reinforcement into the door inner panel as an integral component formed from the same metal sheet. This reduces the total number of separate parts and simplifies the overall structure while maintaining the collision protection function
Solution Approach 2:
The patent extracts the beltline reinforcement function from a separate component and integrates it directly into the door inner panel structure. This eliminates the need for additional fastening mechanisms and assembly steps, reducing device complexity while preserving the reinforcement function
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 results in a high-strength door inner panel with fewer defects, improved collision characteristics, and reduced production costs by integrating the reinforcing function into the panel itself, thus enhancing the vehicle's interior tightness and structural integrity.
Implementation Method 1
heating and hot stamping with a press working apparatus
Implementation Method 2
heating and hot stamping with a press working apparatus to enhance strength and reduce defects like cracks and wrinkles
Data Source
AI summary
A panel-shaped formed product made of a metal sheet includes a top panel portion, an opening portion, and a vertical wall portion. The top panel portion is polygonal. The opening portion is provided in the top panel portion. The vertical wall portion extends from at least not less than two adjacent borders among the borders of the top panel portion. At least one pair of each vertical wall portion of pairs of adjacent vertical wall portions of the vertical wall portions has a stepped portion. As a result, the panel shaped formed product has fewer defects such as cracks and wrinkles even when it has a shape that is difficult to form.