This invention relates generally to reinforced structures. More particularly, the invention relates to reinforced structures used in motor vehicles. In particular, the invention relates to lightweight reinforced structures which can be used as support pillars, frame members and the like for motor vehicles.
Many motor vehicles have a passenger compartment or cargo space which is defined and supported by a framework comprised of a plurality of pillars or other such support members. The support members provide structural integrity to the body of the motor vehicle and serve to protect the occupants or cargo in the event of a crash. In some instances, the support members are configured so as to deform in a controlled manner and thereby absorb kinetic energy in the event of a crash.
Pillars comprising the support framework of a motor vehicle are generally configured as hollow steel bodies. Preferably, the support members combine high strength and low weight. Also, the pillars should be low in cost with regard to both materials and their process for fabrication. Ideally, any such support structure should also be amenable to being manufactured by high speed forming processes such as roll forming, cold stamping and the like.
In early prior art, pillar structures for motor vehicles were typically comprised of simple, hollow, tubular members. Eventually various reinforcing members were included in such structures. In some instances, reinforcing members are disposed on the outside of a hollow pillar, and one such structure is shown in U.S. Pat. No. 5,833,303. In other instances, reinforcing members were disposed, at least partially, internally of pillars and other structural members. Some such reinforced structures are shown in U.S. Pat. Nos. 6,341,467; 3,779,595 and 6,883,858.
The motor vehicle industry is directed toward increasing safety and fuel efficiency of vehicles while keeping costs at a minimum. Hence, there are concurrent needs for decreasing the weight and increasing the strength of the passenger and/or cargo compartments of motor vehicles. Toward that end, the industry is seeking structural components for motor vehicles which combine light weight and high strength; furthermore, such components should be capable of having their deformation characteristics tuned or controlled so as to maximize the absorption of kinetic energy while maintaining sufficient integrity to prevent injuries to passengers or damage to cargo in the event of a crash. As will be explained in detail hereinbelow, the present invention is directed to reinforced structural members which may be incorporated into bodies of motor vehicles. The structural members of the present invention are light in weight, inexpensive to fabricate, and can be configured to provide controlled deformation properties. These and other advantages of the invention will be apparent from the drawings, discussion and description which follow.
Disclosed herein is a structural member of the type which may comprise a support member for the body of a motor vehicle. The structural member comprises a generally elongated pillar or other such support member which at least partially encloses an interior volume, and a reinforcing insert which is disposed within the interior volume and which extends along at least a portion of the length of the support member. The reinforcing insert has a cross section which defines a closed perimeter that encloses an area. In some instances, the reinforcing insert is bonded to the interior surface of the support member, such as by means of an adhesive or mechanical interconnection. In particular embodiments, the reinforcing insert has a cross section which defines two spaced-apart portions which are joined together by a connecting portion. In specific configurations of this embodiment, the spaced-apart portions each comprise a lobe, each lobe having a cross section which defines a perimeter that encloses a separate, respective area. In some instances, the connecting portion may also have a perimeter which defines and encloses a respective area; while in other instances, the connecting portion may be otherwise configured.
In some instances, the support member and/or the reinforcing insert may be made of steel.
Also disclosed herein is a method for making the structural member, as well as the use of the structural member in a motor vehicle body.
The present invention is directed to structural members which may be used for the fabrication of high strength, lightweight frameworks and other support structures. The present invention has particular utility in a support member for the body of a motor vehicle, and will be explained with particular reference to that utility. However, it is to be understood that the present invention may be employed in connection with other structures such as static building structures, protective cages, intrusion barriers, and other constructions wherein high strength, light weight, and controlled deformation characteristics are required.
The structural member of the present invention includes a generally elongated support member which at least partially encloses an interior volume. As such, the support member's structure may comprise a hollow tubular type of member formed from a single body of material or from plural bodies joined together. In other instances, the support member may be partially open, and as such may have a C-shaped profile. The reinforcing insert is disposed in the interior of the pillar so as to extend along at least a portion of its length. In some instances, the reinforcing insert will extend along the entire length of the pillar, and in other instances it may extend along only a portion of the length of the pillar, while in yet other instances a plurality of separate insert members may be disposed in a support member. The reinforcing insert has a cross-sectional profile which defines at least one closed perimeter bounding an area. As will be explained in detail hereinbelow, in some instances, the insert may bound a plurality of internal areas. The insert increases the strength of the support member, particularly with regard to side loading and/or buckling. The cross-sectional profile of the insert may be controlled so as to control the deformation characteristics of the structural member in which it is incorporated.
Various configurations and embodiments of the present invention may be implemented. Referring now to
Disposed within the interior volume of the support member 12 is a reinforcing insert 22. In the
In the illustrated embodiment, the two lobe portions 24, 26 of the insert 22 are joined together by a connector portion 28 which is a simple straight wall structure. As will be detailed hereinbelow, other configurations of insert may be employed in the practice of the present invention.
As shown herein, a back wall portion 30 of the first lobe 24, and a back wall portion 32 of the second lobe 26 are corrugated. One function of these corrugations is to hold an adhesive material therein. For example, a heat activatable, foamable adhesive may be disposed in the corrugations of the insert 22 of
Support members such as the pillar shown in
The support member may be formed to a finished profile and then have the insert placed therein, for example as by threading it through an open end. Or, the support member may be partially fabricated, the insert disposed therein, and the structure then completed so as to enclose the insert. In specific instances, the insert is fabricated from high strength, relatively thin steel, such as a hardenable steel. Both the support member and insert may be fabricated from relatively thin steel stock which can be bent to radii as low as one thickness of the stock material, so as to crowd the profile mass to the outermost tension and compression sides of the structure. In specific embodiments, the components are made out of a material such as aluminum, steel, or aluminized steel having a strength of over 100 ksi. In specific instances, the thickness of the reinforcing member is between 0.5 mm and 2.0 mm, and in yet other instances, the distribution of material between the first 24 and second 26 lobes is approximately 60% and 40% respectively.
The completed structural member may be subjected to further post-fabrication processing and this can involve shaping operations such as roll forming, sweeping, bending, die forming, cutting, drilling, flattening, crushing and the like which change its shape or profile. Likewise, the individual support member and/or reinforcing insert may be subject to such processing steps prior to assembly. Other operations may comprise heating, quenching, welding, brazing, cutting, piercing and the like. For example, the member may be bent, swept, or twisted to form a component such as bumper bar or side intrusion beam for a motor vehicle. In that regard, the member may be heat treated so as to increase its hardness.
Other configurations of reinforcing insert may be utilized in the present invention. For example,
In yet other embodiments of insert, selected deformation may be accomplished by cutting, piercing, or otherwise physically interrupting selected wall portions of the insert. Also, it is to be understood that while the foregoing has primarily described the inserts as being fabricated from metals, polymeric materials, including foamed polymeric materials as well as polymer/metal composites, may be employed to form the insert member.
Referring now to
Referring now to
Support members of various other configurations may also be employed in the practice of the present invention. Such members may include fully and partially closed structures, curved structures, straight structures, and structures of complex shapes. Also, while the support members are primarily described herein as being made of steel, it is to be understood that support members of other materials including metals and synthetic polymers may be utilized.
In view of the teaching presented herein, still further modifications, variations and embodiments of the present invention will be apparent to those of skill in the art. The foregoing drawings, discussion and description are illustrative of only specific embodiments, and are not meant to be limitations upon the practice of the invention. It is the following claims, including all equivalents, which define the scope of the invention.
This application claims priority of U.S. Provisional Patent Application Ser. No. 60/588,118 filed Jul. 14, 2004, entitled “Reinforcement for a B-Pillar of an Automotive Vehicle” and U.S. Provisional Patent Application Ser. No. 60/586,009 filed Jul. 7, 2004 and entitled “Method of Inserting Structural Member in a Roll-Formed Part.”
Number | Date | Country | |
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60588118 | Jul 2004 | US | |
60586009 | Jul 2004 | US |