Motor Vehicle Lock Laser Reinforcement for Crash Load Resistance
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Solution Overview
Problem
Existing motor vehicle closing devices, such as door locks, face challenges in absorbing high crash forces and breaking loads, which can lead to unintended door opening during accidents.
Innovation Solution
The method involves locally reinforcing the base element and closing element of the motor vehicle closing device using laser hardening, and connecting the bearing components of the closing elements to the base element via laser welding, utilizing a fillet or I-seam weld for enhanced strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the base element and closing element are made of solid steel to absorb crash forces, then the strength and reliability improve, but the weight and manufacturing complexity increase
Solution Approach 1:
The patent applies local reinforcement through laser hardening at specific critical areas (recesses for bearing components) rather than making the entire base element uniformly thick. This creates local zones of high strength where needed while keeping other areas lighter, resolving the contradiction between overall strength and weight.
Solution Approach 2:
The patent creates a composite structure by combining base steel material with laser-induced hardened zones. The hardened surface layer has different properties (higher hardness and strength) than the underlying base material, creating a composite effect that provides high strength where needed without requiring the entire component to be made of heavy solid steel throughout.
2Strength
If the material thickness of the lock case is increased to absorb breaking loads, then the strength improves, but the manufacturing complexity and technological effort increase
Solution Approach 1:
Instead of increasing the overall thickness of the lock case uniformly, the patent applies local reinforcement only at critical areas where bearing components are mounted. This is achieved through laser hardening of specific recess zones, providing high strength locally without the complexity of manufacturing a uniformly thick case.
Solution Approach 2:
The patent changes the material properties (hardness, tensile strength) through laser hardening treatment rather than changing the geometric parameter (thickness) of the entire component. This allows achieving high strength through material property modification at critical zones without the manufacturing complexity of producing a uniformly thick structure.
3Reliability
If additional components are used to improve force transmission, then the reliability improves, but the device complexity and manufacturing effort increase
Solution Approach 1:
The patent combines multiple functions into the base element itself: the bearing recesses are directly formed in the base element and laser hardened in place, eliminating the need for separate reinforcement components. The bearing components are then laser welded directly to the hardened recesses, creating an integrated structure that improves reliability without adding separate reinforcement parts.
Solution Approach 2:
The patent replaces mechanical reinforcement (additional steel components, thicker sections) with a thermal process (laser hardening) that modifies the material properties in place. This substitution of manufacturing approach reduces device complexity while maintaining or improving reliability.
4Strength
If the base element is locally hardened to increase tensile strength, then the strength improves, but the manufacturing precision and process complexity increase
Solution Approach 1:
The patent performs preliminary shaping of the recesses in the base element before applying the laser hardening treatment. This preliminary action defines the precise geometry of the recesses, and then the laser hardening is applied to these pre-defined zones, ensuring both precision and strength without requiring the hardening process itself to create the geometry.
Solution Approach 2:
The patent combines the shaping and hardening processes in a continuous manufacturing sequence. The recesses are shaped and then immediately laser hardened in the same manufacturing flow, maintaining precision through continuous processing without interruption or repositioning, thereby reducing the accumulation of manufacturing errors.
5Reliability
If bearing components are laser welded to the base element, then the strength and connection reliability improve, but the manufacturing complexity increases
Solution Approach 1:
The patent merges the bearing component attachment process with the laser hardening process. The same laser source used for hardening the recess is used to weld the bearing components in place, combining two manufacturing steps into one continuous operation. This reduces manufacturing complexity while achieving both hardening and reliable welding connection.
Solution Approach 2:
The laser device is given multiple functions: it first hardens the recess area and then welds the bearing components. This multi-functionality of the laser tool reduces the need for separate manufacturing equipment and processes, thereby reducing overall manufacturing complexity while maintaining high connection reliability.
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 significantly enhances the crash safety and ability to absorb greater breaking loads, ensuring the motor vehicle closing device can withstand high forces without unintended opening during crashes.
Implementation Method 1
the base element is hardened in the region of a recess for the bearing component in question by the laser beam to be used in the region of the recess
Implementation Method 2
the base element and/or the closing element are subsequently at least locally reinforced after the shaping process or is reinforced from the outset
Implementation Method 3
bearing components of the closing element are connected to the base element by means of laser welding
Implementation Method 4
One or both bearing components are then connected to the base element by means of laser welding
Data Source
AI summary
A method for producing a motor vehicle closing device and in particular to a motor vehicle lock. Said motor vehicle lock is equipped with at least one metallic base element and a closing element. The base element and/or the closing element is subsequently at least locally reinforced after its shaping process or is equipped with such a reinforcement from the outset. According to the invention, bearing components of the closing element are connected to the base element by means of laser welding.