Vehicle Pillar With Single-Layer Flange and Variable Thickness
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Solution Overview
Problem
Existing vehicle pillars lack a lightweight and easy-to-connect design, as they often require complex welding processes and material duplication, which increases weight and complexity.
Innovation Solution
A vehicle pillar design featuring a hot-stamped and hardened outer panel and a cold-stamped inner panel, connected via a high-energy beam weld seam with a single-layer flange section, allowing for a stable and lightweight structure with variable thickness for optimized load distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If both the inner panel and outer panel are welded together in overlapping configuration, then connection stability is improved, but material duplication increases weight
Solution Approach 1:
The vehicle pillar is segmented into three distinct zones: an inner panel region, an outer panel region, and a transition zone where they connect. The inner panel and outer panel are positioned such that they do not overlap in the longitudinal direction, creating separate functional zones that reduce material duplication while maintaining structural integrity through the transition zone
Solution Approach 2:
The connection between inner and outer panels is achieved through a lateral offset in the longitudinal dimension rather than through overlapping in the transverse dimension. This dimensional approach allows the panels to connect via a transition zone without material duplication, reducing weight while maintaining connection stability
2Ease of manufacture
If the outer panel is offset relative to the inner panel to create a single-layer flange section, then welding ease is improved, but structural complexity increases
Solution Approach 1:
The vehicle pillar structure is divided into distinct segments with a single-layer flange section that is separated from the overlapping regions. This segmentation creates a dedicated welding zone that is accessible and suitable for welding operations, while the rest of the structure maintains its load-bearing configuration
Solution Approach 2:
The single-layer flange section is created locally at specific positions where welding is required, rather than throughout the entire structure. This local modification provides welding accessibility where needed while maintaining the load-bearing overlapping configuration in other critical areas, thus balancing manufacturing ease with structural integrity
3Strength
If the outer panel has variable thickness, then load distribution is optimized, but manufacturing complexity increases
Solution Approach 1:
The outer panel is designed with variable thickness where it is subjected to different load conditions. Thicker sections are provided in high-stress areas to enhance load-bearing capacity, while thinner sections are used in low-stress areas to reduce weight. This local variation in thickness optimizes the overall strength-to-weight ratio of the vehicle pillar
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 design enables a lightweight, stable, and easily connectable vehicle pillar with reduced material duplication, improved welding efficiency, and adaptable thickness for enhanced crash behavior and market-specific strength.
Implementation Method 1
the inner panel and the outer panel being connected to one another by means of a high-energy beam weld seam along a connecting edge of the connecting section
Implementation Method 2
the outer panel is a hot stamped and hardened molding
Data Source
Figure 1~2
Figure 3~6
Figure 7~8
AI summary
The present invention relates to a structural component 1; 21; 31; 41, in particular for a motor vehicle body, comprising a cold-formed first molded part 2; 32; 42, and a hot-formed and hardened second molded part 3; 23; 33 with a variable thickness over a longitudinal extent L2 of the second molded part 3; 23; 33, wherein the second molded part 3; 23; 33 has a connecting section 7; 27; 37 for connecting to the first molded part 2; 32; 42, which is spaced apart from an outer edge 13 of the first molded part 2; 32; 42 such that the structural component 1; 21; 31; 41 has a single-layer flange section 12 of the first molded part 2; 32; 41 between the connecting section 7; 27; 37 and the outer edge 13. 42, wherein the first molded part 2; 32; 42 and the second molded part 3; 23; 33 are joined together by means of a high energy beam weld 19 along a connecting edge 18 of the connecting section 7; 27; 37.Furthermore, the present invention relates to a method for manufacturing a structural component 1; 21; 31; 41.