• 专利附录
  • 专利说明
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    • 专利摘要:
    LIGHT STEEL DOOR FOR VEHICLE AND METHOD FOR MANUFACTURING THE SAME. The present invention relates to a vehicle door assembly comprising an inner panel (12) in the form of a frame portion. The frame portion (28) comprises opposing front and rear U-shaped side frames (281, 282) that are not releasably attached to each other by upper and lower intermediate frame members (283, 284) to form a continuous perimeter. The side frame members are made of a first steel material and the intermediate frame members are made of a second steel material, which is different from the first steel material. One method for manufacturing the inner panel comprises providing U-shaped blades (52F, 53R) of the first steel material, providing upper and lower blades (54T, 54B) of the second steel material, connecting the blades in a non-releasable manner U shape to the upper and lower blades to form a blank, and press the blank into the frame portion.
    公开号:BR112014007461B1
    申请号:R112014007461-5
    申请日:2012-10-01
    公开日:2021-01-05
    发明作者:Paul SCHURTER；Timothy Lim；Paul DOLAN；Hamed SHARIFI
    申请人:ArcelorMittal Investigación y Desarrollo, S.L.；
    IPC主号:
    专利说明:

    FIELD OF THE INVENTION
    [001] The present invention relates, in general, to vehicle door assemblies and methods for manufacturing them and, more particularly, to a light vehicle door assembly and to a method for manufacturing the same with the use of components made from various interconnected high strength steel grades. CROSS REFERENCE TO A RELATED ORDER
    [002] This Order claims the benefit under 35 USC 119 (e) of Provisional Order No. Serial US 61 / 541,568 filed on September 30, 2011 by Schurter et al., Which is fully incorporated into this document by way of reference and to which priority is claimed. BACKGROUND OF THE INVENTION
    [003] Conventionally, vehicle doors comprise an internal support panel made of a steel material. An external panel is attached to the internal panel. The conventional inner panel is produced by deep drawing from steel May. A waistline beam under the window is welded to the inner panel and can be placed on the inside or outside of the window. Typically, vehicle doors include a side impact protection beam that extends generally horizontally made of steel that has a considerably higher mechanical strength than the steel from which the inner panel is made. The impact protection beam is welded to the inner panel and placed closer to the outer panel. A relatively flat chip is attached to the inner panel. The internal components of the door, such as latches, window guides and window lifts, are mounted to the internal panel.
    [004] Furthermore, the steel blade has been the most widely used raw material for motor vehicle doors. Steel doors are inexpensive and simple to manufacture. However, conventional steel door designs are relatively heavy compared to the mass of newly designed aluminum doors. Consequently, there is a tendency in the automotive industry to replace steel doors with doors made of aluminum. Although lighter than conventional steel doors, aluminum doors do, however, are more expensive than steel doors and are more complex, difficult and costly to manufacture.
    [005] Therefore, vehicle doors made of steel are susceptible to improvements that can improve their cost and weight performance. With that in mind, there is a need to develop an improved vehicle door made of high-strength steel with reduced weight compared to the weight of aluminum doors, with improved performance and low cost manufacturing. SUMMARY OF THE INVENTION
    [006] The present invention is directed to an innovative light vehicle door assembly and a method for manufacturing it.
    [007] The vehicle door assembly according to the present invention comprises an internal panel in the form of a substantially rectangular frame portion that has a continuous perimeter formed entirely by upper and lower horizontal beams interconnected by front and rear vertical beams and one external panel attached to the internal panel. The frame portion comprises opposite front and rear U-shaped frame members releasably secured to each other by upper and lower intermediate frame members so as to form a continuous perimeter. The side frame members are made of a first steel material and the intermediate frame members are made of a second steel material. The first steel material of the side frame members is different from the second steel material of the intermediate frame members.
    [008] The method for manufacturing an internal panel of a vehicle door assembly according to the present invention comprises the steps of providing front and rear flat U-shaped steel sheets of a first steel material so that each of the front and rear U-shaped steel blades comprises a cross portion and a pair of leg portions spaced from each other extending from the cross portion, providing upper and lower flat steel blades of a second material steel, connect each leg portion of each of the U-shaped steel blades in a non-releasable manner to a respective blade between the upper and lower steel blades to form a flat door perimeter frame blank and pressing the door perimeter frame blank into a portion of the perimeter frame of an inner panel. The first steel material of the front and rear flat U-shaped steel blades is different from the second steel material of the upper and lower flat steel blades. In addition, the frame portion comprises opposing front and rear U-shaped frame members releasably secured to each other by upper and lower intermediate frame members so as to form the continuous perimeter. The side frame members are made of the first steel material and the intermediate frame members are made of the second steel material, which has superior strength and thickness to improve resistance to lateral intrusion. BRIEF DESCRIPTION OF THE DRAWINGS
    [009] The attached drawings are incorporated in the specification and form part of it. The drawings, together with the general description provided above and the detailed description of the exemplary modalities and methods provided below, serve to explain the principles of the invention. In such drawings: Figure 1 is a side view of a front door assembly on the right side of a vehicle according to an exemplary embodiment of the present invention; Figure 2A is a partial perspective view of the front door assembly on the right side of a vehicle according to the exemplary embodiment of the present invention; Figure 2B is a partial perspective view of the front door assembly on the right side of a vehicle according to an alternative embodiment of the present invention; Figure 3 is a sectional view of the front door assembly on the right side of a vehicle according to the exemplary embodiment of the present invention; Figure 4 is an exploded assembly drawing in perspective of the front door assembly on the right side of a vehicle according to the exemplary embodiment of the present invention; Figure 5 is an exploded assembly drawing in perspective of structural elements of the front door assembly on the right side of a vehicle according to the exemplary embodiment of the present invention; Figure 6 is a perspective view of an internal panel of the front door assembly on the right side of a vehicle according to the exemplary embodiment of the present invention; Figure 7 is a side view of the inner panel of Figure 6; Figure 8 is a top view of the inner panel of Figure 6; Figure 9A is a side view of a laser welded blank with multiple parts for pressing a frame portion of the inner panel according to the exemplary embodiment of the present invention; Figure 9B is a side view of the frame portion of the inner panel according to the exemplary embodiment of the present invention pressed from the multi-piece laser welded blank shown in Figure 9A; Figure 10 is a side view of the inner panel according to the exemplary embodiment of the present invention, which shows lines in cross section; Figure 11 is a cross-sectional view of the inner panel of Figure 6 taken along line 1-1 shown in Figure 10; Figure 12 is a cross-sectional view of the inner panel of Figure 6 taken along line 2-2 shown in Figure 10; Figure 13 is a cross-sectional view of the inner panel of Figure 6 taken along line 3-3 shown in Figure 10; Figure 14 is a cross-sectional view of the inner panel of Figure 6 taken along line 4-4 shown in Figure 10; Figure 15 is a cross-sectional view of the inner panel of Figure 6 taken along line 5-5 shown in Figure 10; Figure 16 is a cross-sectional view of the inner panel of Figure 6 taken along line 6-6 shown in Figure 10; Figure 17 is a cross-sectional view of the inner panel of Figure 6 taken along line 7-7 shown in Figure 10; and Figure 18 is a cross-sectional view of the inner panel of Figure 6 taken along line 8-8 shown in Figure 10. DETAILED DESCRIPTION OF EXEMPLIFICATIVE MODE (S) AND EXEMPLIFICATIVE METHOD (S)
    [0010] Reference will now be made in detail to the exemplary modalities and methods of the invention as illustrated in the accompanying drawings, in which similar reference characters designate similar or corresponding parts throughout the drawings. It should be noted, however, that the invention in its broadest aspects is not limited to methods, representative devices and specific details, and illustrative examples shown and described in connection with the exemplary modalities and methods.
    [0011] This description of exemplary modalities is intended to be read in connection with the attached drawings, which should be considered part of the entire written description. In the description, relative terms such as "horizontal", "vertical", "front", "back", "top", "bottom," top ", and" bottom "as well as derivatives thereof (for example," horizontally " , "down", "up", etc.) are to be interpreted as referring to the orientation as described or as shown in the figure in the drawing under discussion and to the guidance relating to a vehicle body. These relative terms are for convenience of description and are not normally intended to require particular guidance. Terms dealing with fixations, coupling and the like, such as "connected" and "interconnected" refer to a relationship in which structures are attached or fixed to each other directly or indirectly through intervention structures, as well as rigid or mobile relationships or fixations, unless expressly described otherwise. The term "operationally connected" is a type of fixation, coupling or connection that allows to the relevant structures operate as desired through that relationship. In addition, the word "one" as used in the claims means "at least one (a)".
    [0012] Figures 1, 2A, 3, 4 and 5 illustrate a right-hand front door assembly 10 of a motor vehicle (especially a medium-sized car) according to an exemplary embodiment of the present invention. The door assembly 10 comprises an inner panel 12, an outer panel 14 attached to and supported by the flanges of the inner panel 12, a module extension 16 used to receive a pre-assembled door module unit, attached to an inner surface and supported by it (that is, facing a passenger compartment of the motor vehicle) of the inner panel 12, an inner waistline element (or beam) 15 (shown in Figures 4 and 5) disposed between the inner panel 12 and the module extension 16, a hinge reinforcement member 18 attached to a front end 12F of the inner panel 12, a window frame 20 for a window panel 21 that can be moved in and out of a cavity 11 formed between of the door assembly 10 between the inner panel 12 and the module extension 16 (as shown in Figure 3) and a front window guide 26.
    [0013] The inner panel 12, according to the exemplary embodiment of the present invention shown in detail in Figures 4 to 8, is a pressed three-piece subassembly that includes a substantially rectangular perimeter frame portion 28 that has a continuous perimeter, a single intermediate (vertical) upright beam (structural element) 38 and a single front (or gusseted) transverse beam (structural element) 40 which are both releasably attached to the perimeter frame portion 28 to stiffen the inner panel 12, supply lateral intrusion protection support the external thin gauge panel 14 to improve its rigidity and oil conservation performance. Each of the intermediate vertical beam 38 and the gusset beam 40 has an open hat shape profile and is formed separately from the perimeter frame portion 28. The perimeter frame portion 28, the intermediate vertical beam 38 and the gusset beam 40 is then releasably attached to each other, such as by welding, and preferably by laser welding, to form the inner panel 12. The perimeter frame portion 28 of the inner panel 12 is formed entirely by the upper and lower horizontal beams 30 and 32, respectively, interconnected by the front and rear vertical beams 34 and 36, respectively.
    [0014] As illustrated in detail in Figures 6 and 7, the intermediate vertical beam 38 extends substantially vertically between the upper and lower horizontal beams 30 and 32 approximately through the middle of the frame portion 28 of the inner panel 12, while the front crossbeam 40 is angled so that it extends between the upper horizontal beam 30 and the front upright beam 34. The gusset beam 40 acts as an arm between the front upright beam 34 (and the hinge member 18) and the upper horizontal beam 30 under the window frame 20. This reinforces the door assembly 10 to improve stiffness. Alternatively, the inner panel 12 may include only the single intermediate vertical beam 38, but not the gusseted beam 40. The upright vertical beam 38 together with the inner panel 12 and the gusseted beam 40 provide an effective means of resisting impact intrusions. side. Thus, according to the exemplary embodiment of the present invention, the inner panel 12 of the door assembly 10 lacks a conventional horizontal intrusion beam (or side impact protection beam) that extends substantially horizontally between the vertical front beams and posterior (structural elements) 34 and 36. The waistline beams (i.e., the upper horizontal beam 30 and the inner waistline beam 15) provide rigidity.
    [0015] The internal panel 12 of the door assembly 10 is manufactured from Advanced High Strength Steel (AHSS). The method of manufacturing the inner panel 12 of the door assembly 10 according to the exemplary embodiment of the present invention is described below. First, as best shown in Figure 9A, a single, substantially rectangular flat perimeter frame bracket 50 having a continuous perimeter is formed integrally from four pieces of steel sheet in order to manufacture the portion of multi-piece frame 28 of the inner panel 12. The steel blade parts include two opposing front and rear flat U-shaped steel blades 52F and 52R, respectively, of a first advanced high-strength steel material, and two substantially opposite rectangular top and bottom flat steel blades 54T and 54B, respectively, of a second high strength advanced steel material, which is different from the first steel material and has superior thickness and strength to improve resistance to lateral intrusion .
    [0016] Subsequently, the single laser welded blank 50 is pressed into the perimeter frame portion 28 of the inner panel 12 by hot pressing or cold pressing.
    [0017] According to the exemplary embodiment of the present invention, in the case of cold pressing of the perimeter frame crude 50, the first steel material is a steel of class DP 780 which has a thickness (or gauge) of 0, 60 mm, while the second steel material is an MS1300 grade martensitic steel that has a thickness of 1.00 mm. It should be understood that the steel material is characterized by class (hence strength) and thickness (or gauge). For example, a class of TRIP steel can be used instead of high-strength steel of class DP 780 if there is a need to increase plasticity in the perimeter frame crude 50. In addition, the particular classes of the first and second materials of steel used in the case of hot pressing of the perimeter frame crude 50 are different from those used during cold pressing. However, in any case, the second steel material is different from the first steel material and has superior strength and thickness.
    [0018] Each of the 52F, 52R front and rear U-shaped steel blades comprises a cross portion 52FC, 52RC and a pair of leg portions spaced apart 52F1 and 52F2, 52R1 and 52R2 extending from of the 52FC, 52RC cross-section. In order to form the steel crude 50, the front and rear flat U-shaped steel blades 52F and 52R are oriented so that the leg portions 52F1, 52F2 and 52R1, 52R2 are aligned and facing each other. Then, the upper and lower steel blades 54T and 54B are placed between the leg portions 52F1 and 52F2, 52R1 and 52R2 of the U-shaped steel blades 52F, 52R in order to be aligned with them. Subsequently, each of the leg portions 52F1 and 52F2, 52R1 and 52R2 of each of the 52F U-shaped steel sheets, 52R is connected in a non-releasable (ie fixed) manner to a free end of the same to the sheets of steel. respective upper and lower steel 54T and 54B by any appropriate means known in the art to form the crude steel 50. According to the exemplary embodiment of the present invention, U-shaped steel blades 52F, 52R have welded folds to the upper and lower steel blades 54T and 54B, such as by laser welding, thus forming a single laser welded blank 50. As a result, the single blank 50 contains different steel materials, ie grades and / or different gauges of advanced high strength steel. Specifically, the leg portions 52F1 and 52R1 of the front and rear flat U-shaped steel blades 52F and 52R, respectively, have the folds welded to the distal ends of the upper steel blade 54T through the laser welded joints 531 and 533, while the leg portions 52F2 and 52R2 of the front and rear flat U-shaped steel blades 52F and 52R, respectively, have the folds welded to the distal ends of the lower steel blade 54B through the laser welded joints 532 and 534.
    [0019] Subsequently, the single laser welded blank 50 is pressed into the perimeter frame portion 28 of the inner panel 12 by hot pressing or cold pressing. In the case of hot pressing, the flat steel crude 50 is first heated, then placed on a forming tool to create the required shape of the frame portion 28, then the hot pressed frame portion 28 remains on the tool at as it is cooled quickly to increase its resistance.
    [0020] The pressed frame portion 28 of the inner panel 12, illustrated in detail in Figure 9B, includes opposite front and rear U-shaped side frame members 281 and 282 (pressed from the flat U-shaped steel blades front and rear 52F and 52R) releasably attached to each other by the upper and lower intermediate frame members 283 and 284 (pressed from the upper and lower steel blades 54T and 54B), spaced apart, in order to form the continuous perimeter. Furthermore, according to the exemplary embodiment of the present invention, leg portions of the front and rear side frame members 281 and 282 have the folds welded to the distal ends of the upper and lower intermediate frame members 283 and 284 through the laser welded joints 531, 532, 533 and 534. Thus, the frame portion 28 of the inner panel 12 is integrally formed by the front and rear U-shaped side frame members 281 and 282 interconnected by the upper and lower intermediate frame members 283 and 284.
    [0021] Furthermore, as mentioned above, in the case of cold pressing of the perimeter frame crude 50, the side frame members 281 and 282 of the frame portion 28 are made of grade steel DP 780 which has a thickness of 0 , 60 mm, while the upper and lower intermediate frame members 283 and 284 are made of grade MS1300 martensitic steel that has a thickness of 1.00 mm. Thus, the steel material of the side frame members 281 and 282 is different from the steel material of the upper and lower intermediate frame members 283 and 284 (i.e., it has a different grade and / or gauge).
    [0022] Next, each of the intermediate vertical beam 38 and the gusset beam 40 is hot or cold pressed separately from frame portion 28 and one from the other. In other words, each of the intermediate vertical beam 38 and the gusset beam 40 according to the exemplary embodiment of the present invention is a one-piece hot or cold pressed member. The intermediate vertical beam 38 is pressed from a very thin gauge flat blade of a high-strength steel crude from a third steel material, such as 1500P USIBOR® which has a thickness of 0.60 mm, which is different of the first steel material of the side frame members 281 and 282 and the second steel material of the intermediate frame members 283 and 284. Similarly, the gusset beam 40 is pressed from a very thin gauge flat blade of a high-strength steel crude of a third steel material, such as 1500P USIBOR® which has a thickness of 0.60 mm, which is different from the first steel material of the side frame members 281 and 282 and the second material of steel of intermediate board members 283 and 284.
    [0023] Currently, the minimum thicknesses of hot-pressed steel parts are about 0.90 mm. 1500P USIBOR® is a hardenable boron alloy steel coated with an Al-Si coating from ArcelorMittal often used when high strength is required. Aluminum-silicon coatings protect the steel against oxidation during heating and provide corrosion protection for the component. In the case of a hot pressing process, manufacturing is carried out on a press hardening line, in which a heated steel crude (900 ° C) is formed and then quickly cooled (briskly cooled) to room temperature in a tool of formation cooled with water. The result is a hardened part with a proportioned strength of about 1,100 MPa and a final strength of about 1,500 MPa.
    [0024] Finally, the frame portion 28, the intermediate vertical beam 38 and the gusset beam 40 are joined together in a non-releasable manner after pressing (such as welded and, preferably, laser welded) to form the internal multipart 12 as shown in Figures 6 to 8.
    [0025] As best shown in Figures 6 and 7, the intermediate vertical beam 38 extends substantially vertically between the upper and lower horizontal beams 30 and 32 approximately through the middle of the perimeter frame portion 28 of the inner panel 12 of so that the distal ends of the intermediate vertical beam 38 are releasably attached to the upper and lower intermediate frame members 283 and 284 of the perimeter frame portion 28. Thus, the intermediate vertical beam 38 extends between the thickest sections of the portion of frame 28. In turn, the gusset beam 40 extends between the upper horizontal beam 30 and the front upright beam 34 so that the distal ends of the gore beam 40 are releasably attached to the upper intermediate frame member 283 and the front side frame member 281 of the frame portion 28.
    [0026] As mentioned above, each of the intermediate vertical beam 38 and the gusset beam 40 is hot or cold pressed separately from the frame portion 28 and one from the other. Alternatively, the inner panel 12 can be created in the form of a one-piece hot or cold pressed member.
    [0027] As further illustrated in detail in Figures 6 and 7, the intermediate vertical beam 38 and the gusset beam 40 define three openings 42, 44 and 46 in the inner panel 12. The openings 42, 44 and 46 are formed within the portion rectangular frame 28 (defined by horizontal beams 30, 32 and upright beams 34, 36) by the intermediate vertical beam 38 and by the gusseted beam 40. Specifically, the first opening 42 is defined between the upper and lower horizontal beams 30 and 32 , the rear upright beam 36 and the intermediate vertical beam 38. The second opening 44 is defined between the gusset beam 40, the front upright beam 34, the lower horizontal beam 32 and the intermediate vertical beam 38. The third opening 46 is defined between the upper horizontal beam 30, the gusset beam 40 and the front upright beam 34. Alternatively, the gusset beam 40 and the opening 46 do not need to be provided.
    [0028] According to the exemplary embodiment of the present invention, as shown in Figures 10 and 12 to 16, each of the lower horizontal beam 32, the front upright beam 34 and the rear upright beam 36 of the frame portion 28 have a open hat-shaped profile with a crown portion 33C, 35C and 37C, respectively, and a pair of separate flanges 33F, 35F and 37F, respectively, extending from the crown portion in the direction away from the inner part ( that is, a passenger compartment) of the vehicle and towards the outer panel 14 of the door assembly 10. Furthermore, each of the flanges 33F, 35F and 37F is provided with a flap 33L, 35L and 37L, respectively, which extends from a distal end of it. Each of the flaps 33L, 35L and 37L is shaped and dimensioned to find (if engaged with) an internal surface of the external panel 14.
    [0029] As further illustrated in Figures 6 to 8, 10 and 18, the upper horizontal beam 30 includes a main portion 31M and a flange 31F extending from the main portion 31M in the direction away from the inside (i.e., the passenger compartment) of the vehicle and towards the outer panel 14 of the door assembly 10. The flange 31F is provided with a flap 31L extending from a distal end thereof. Each of the flaps 31L is shaped to find (engage) an internal surface of the outer panel 14. The main portion 31M extends substantially vertically in the direction of the crown portion 33C, 35C and 37C of the lower horizontal beam 32, frontal upright beam 34 and posterior upright beam 36 of the frame portion 28.
    [0030] Additionally according to the exemplary embodiment of the present invention, as shown in Figures 10, 11 and 17, both the intermediate vertical beam 38 and the gusseted beam 40 have an open hat-shaped profile, each of which has a crown portion 39C and 41C, respectively, and a pair of separate flanges 39F and 41F, respectively, extending from the crown portion 39C, 41C in the direction away from the inside (i.e., the passenger compartment) of the vehicle and towards the outer panel 14 of the door assembly 10. Furthermore, each of the flanges 39F and 41F is provided with a flap 39L and 41L, respectively, which extends from the end thereof. Each of the flaps 39L and 41L is shaped to find (if engaging) an internal surface of the external panel 14.
    [0031] The front end 12F of the inner panel 12 is an end portion of the inner panel 12 in which the door assembly 10 is swiveled to a front pivot pillar (A pillar) of a motor vehicle body by at least at least one articulation member through the articulation reinforcement member 18. Preferably, the inner panel 12 is pivotally suspended from the front articulation pillar (pillar A) of the vehicle body by two articulations and has the integrated articulation reinforcement member 18 welded to the front end 12F of the inner panel 12. A rear end 12R of the inner panel 12 is an end portion of the inner panel 12 in which a latch for the door assembly 10 is provided to cooperate with a middle pillar (B pillar ) of the motor vehicle body. As mentioned above, the hinge reinforcement member 18 is attached to the front end 12F of the inner panel 12. According to the exemplary embodiment of the present invention, the hinge reinforcement member 18 is formed from a laser welded blank of three separate pieces of high strength steel blade, as shown in Figure 5, integrally attached to each other, as shown in Figure 4: a primary piece 181 made of double-phase steel such as DP 600 that has a thickness of 0, 60 mm and two vertically spaced secondary parts 182, each of which is made of a double-phase steel such as DP 980 which has a thickness of 1.50 mm. Each of the secondary parts 182 of the hinge reinforcement member 18 can be provided with two washers 183, each of which is made of a double-phase steel such as DP 600 which has a thickness of 3.50 mm. Alternatively, the hinge reinforcement member 18 can be made from other grades and steel gauges. In other words, the hinge reinforcement member 18 is formed from a laser welded blank which includes primary steel part 181 and two secondary steel parts 182 of welded folds within the single laser welded blank, the which is then pressed into a final part (the hinge reinforcement member 18) which includes different grades (or types) and thickness of steel.
    [0032] The outer panel 14 according to the exemplary embodiment of the present invention is adhesive-bonded to the flaps 31L, 33L, 35L, 37L, 39L and 41L of flanges 31F, 33F, 35F, 37F, 39F and 41F, respectively, the inner panel 12, closing the hat-shaped sections of the lower horizontal beam 32, the front upright beam 34 and the rear upright beam 36 of the frame portion 28, and the intermediate gusseted and upright beams 38 and 40 and forming a structure even more resistant and rigid internal. As best shown in Figures 4 and 5, spheres 17 of an appropriate adhesive material are deposited between the flaps 31L, 33L, 35L, 37L, 39L and 41L of the inner panel 12 and the outer panel 14. This allows the outer panel 14 stabilize the flanges 31F, 33F, 35F, 37F, 39F and 41F of the inner panel 12 during side intrusion events, thus improving the resistance of door assembly 10 to lateral intrusion. In the exemplary embodiment of the present invention shown in Figure 5, the balls 17 of the adhesive material are deposited on an inner surface of the outer panel 14 so that they face the flaps 31L, 33L, 35L, 37L, 39L and 41L of the inner panel 12 Alternatively, the balls 17 of the adhesive material are deposited directly on the flaps 31L, 33L, 35L, 37L, 39L and 41L of the inner panel 12. Preferably, the adhesive material used to adhesively bond the outer panel 14 to the inner panel 12 is a structural adhesive that has sufficient bond strength to adhere the internal and external panels 12 and 14 without causing a "read-through" effect on the outside of the external panel 14.
    [0033] In accordance with the exemplary embodiment of the present invention, the outer panel 14 is formed of a steel blade, such as ArcelorMittal exposed double-phase FF280DP quality steel, which has a thickness of about 0.55 mm . The lightweight outer panel made of high-strength, thin-gauge steel 14 reduces the weight of the vehicle door compared to conventional heavier and lower-gauge designs without compromising dent resistance. The lightweight external panel 14 made of 0.55 mm class FF280DP high strength steel maintains a required dent resistance in minimum mass. The outer panel 14 structurally connected to the inner panel 12 allows the outer panel 14 to function synergistically with the inner panel 12 to achieve performance requirements.
    [0034] The module extension 16 according to the exemplary embodiment of the present invention is formed of a double-phase steel such as class DP500 which has a thickness of about 0.50 mm, or other suitable steel grades and gauges . The inner waistline beam 15 is fixed between the upper horizontal beam 30 of the inner panel 12 and the module extension 16 and is formed of a hot-pressed high-strength steel such as 1500P USIBOR® that has a thickness of about 0.50 mm, or other suitable steel grades and gauges. An internal waistline support 19 is made of a steel grade DP500 that has a thickness of 0.55 mm in the exemplary embodiment of the present invention.
    [0035] As further illustrated in Figures 4 and 5, the window frame 20 comprises an external window frame member 22 and an internal window frame member 24 facing the vehicle passenger compartment. The outer and inner window frame members 22, 24 are welded together and to the inner panel 12, preferably by spot or laser welding. The outer and inner window frame members 22 and 24 can be formed by cold or hot pressing from multi-piece laser welded roughs with laser welded joints staggered between the outer and inner window frame members 22, 24 of the window frame 20. Alternatively, the outer and inner window frame members 22 and 24 can be formed by lamination. The external window frame member 22 according to the exemplary embodiment of the present invention, shown in detail in Figures 4 and 5, is made up of three separate pieces 221, 222 and 223, which are integrally attached to each other, such as by laser welding through laser welded joints 231 and 232. The outer window frame member 22 is manufactured, first, by providing the first, second and third flat sheets made of the first, second and second third external window steel materials, respectively, which are different from each other. Then, the first, second and third flat blades are releasably attached to each other to form a single outer window blank. Then, the outer window blank is pressed into the single outer window frame member 22.
    [0036] According to the exemplary embodiment of the present invention, the first part 221 of the external window frame member 22 is made of a grade BH210 steel with a thickness of 0.50 mm (first external window steel material) , the second part 222 is made of steel grade DP500 which has a thickness of 0.55 mm (second external window steel material), while the third part 223 (a portion of mirror flare) is made of steel Class 1500P USIBOR® which has a thickness of 0.50 mm (third external window steel material). Alternatively, other suitable steel grades and gauges can be used.
    [0037] The internal window frame member 24 according to the exemplary embodiment of the present invention, shown in detail in Figures 4 and 5, is made of two separate pieces 241 and 242, which are integrally fixed to each other , such as by laser welding via a laser welded joint 25. The inner window frame member 24 is manufactured, first, by providing a first and a second flat strip with first and second material internal window steel, respectively. Then, the first and second flat blades are releasably attached to each other to form a single inner window blank. Then, the inner window blank is pressed into the single inner window frame member. The first and the second inner window steel materials are different from each other.
    [0038] In accordance with the exemplary embodiment of the present invention, the first part 241 of the external window frame member 22 is made of steel grade DP500 which has a thickness of 0.58 mm (first steel material of internal window) ), while the second part 242 (which includes a mirror beacon portion) is made of a double-stage DP 600 steel that has a thickness of 0.76 mm (according to internal window steel material). Alternatively, other suitable steel grades and gauges can be used.
    [0039] The front window guide 26, normally an added component used only for fixing glass, is used in the present project as a structural element that provides rigidity to the mirror flag and rigidity to the structure of the upper window frame. In addition, the front window guide 26 stiffens the mirror beacon area of the window frame 20. In accordance with the exemplary embodiment of the present invention, the front window guide 26 is made of Special DQSK Quality Steady Steel that has a thickness of 0.80 mm (or other suitable steel grades and gauges). A window guide support 27 is made of steel grade DP780 which has a thickness of 0.50 mm in the exemplary embodiment of the present invention.
    [0040] As shown in Figures 2A and 6 to 8, the rear upright beam 36 of the inner panel 12 is provided with a deep drawing section 29 in contact with the inner window frame member 24. Alternatively, as shown in Figure 2B , a deep drawing section 29 'can be integrated within the inner window frame member 24 (i.e., formed as a single piece with the same) of the window frame 20 for better manufacturing potential and possibly better performance structural.
    [0041] The present invention provides a light steel door assembly for a vehicle creating optimized load paths and making each component in the door assembly have multiple strengthening and stiffening functions. The door assembly according to the present invention provides a weight reduction in a steel solution that approximates that of an aluminum solution, while maintaining the required strength and stiffness, at a total manufacturing cost that is substantially lower than those aluminum solutions. The present invention employs a load path optimization to develop an efficient structure (that is, it places structural elements along important load paths). This maximizes efficiency and ties all components of the door assembly together so that each performs multiple functions to achieve the passenger compartment side protection performance objectives, structural door stiffness and strength. The present invention additionally uses innovative material applications, hot and / or cold pressing and laser welding. The door assembly of the present invention includes an inner panel comprising a hot or cold pressed frame portion from a multi-piece laser welded blank, and intermediate upright and cold gusset beams separately hot or cold pressed. not releasably connected to the frame portion. The hot press design also provides strength and stiffness in the waistline area, eliminating the need for additional reinforcements in this area. The unique architecture of the door, with the internal reinforcement panel arranged outside the glass window panel and supported by the external panel, provides improved lateral intrusion and stiffness behavior.
    [0042] The previous description of the exemplary embodiments of the present invention has been presented for purposes of illustration in accordance with the provisions of the Patent Statutes. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obvious variations and modifications are possible in light of the above teachings. The modalities disclosed above in this document have been chosen in order to better illustrate the principles of the present invention and its practical application to allow those of ordinary skill in the art to make better use of the invention in various modalities and with various modifications according to the particular use provided that the principles described in this document are followed. Thus, changes can be made to the invention described above without departing from its intention and scope. It is also intended that the scope of the present invention is defined by the claims attached to it.
    权利要求:
    Claims (33)
    [0001]
    1. Vehicle door assembly (10) comprising: an internal panel (12); and an external panel (14) attached to said internal panel (12); characterized by the fact that said inner panel (12) includes: - a portion of a substantially rectangular frame (28) that has a continuous perimeter formed entirely by upper and lower horizontal beams (30, 32) interconnected by front and rear vertical beams ( 34, 36), said frame portion (28) comprising opposite front and rear U-shaped side frame members (281 and 282) fixed in a non-releasable manner by upper and lower intermediate frame members ( 283 and 284) so as to form said continuous perimeter; - a single vertical beam (38) extending between said upper and lower horizontal beams (30 and 32) of said frame portion (28); and - a single gusset beam (40) fixed non-releasably to said frame portion (28) and inclined so as to extend between said front U-shaped side frame member (281) and said front member upper intermediate frame (283); said frame members (281 and 282) being made of a first steel material and said intermediate frame members (283 and 284) being made of a second steel material; the first steel material of said side frame members (281 and 282) being different from said second steel material of said intermediate frame members (283 and 284); said intermediate vertical beam (38) fixed non-releasably to said intermediate frame members (283 and 284) of said frame portion (28) at distal ends thereof; said intermediate vertical beam (38) made of a third steel material different from the second steel material of said intermediate frame members (283 and 284); said gusset beam (40) made of a fourth steel material different from said second steel material of said intermediate frame members (283 and 284).
    [0002]
    2. Vehicle door assembly (10) according to claim 1, characterized in that said second steel material of said intermediate frame members (283 and 284) is thicker than said first steel material of said side frame members (281 and 282).
    [0003]
    3. Vehicle door assembly (10) according to claim 1, characterized in that said first steel material of said side frame members (281 and 282) is different from said third steel material of said intermediate vertical beam (38).
    [0004]
    4. Vehicle door assembly (10) according to claim 3, characterized in that said second steel material of said intermediate frame members (283 and 284) is thicker than said first material steel of said side frame members (281 and 282) and thicker than said third steel material of said intermediate vertical beam (38).
    [0005]
    5. Vehicle door assembly (10) according to claim 3 or 4, characterized in that said first steel material of said side frame members (281 and 282) is different from said fourth steel material of said gusset beam (40).
    [0006]
    6. Vehicle door assembly (10) according to claim 3, characterized by the fact that said third steel material of said intermediate vertical beam (38) is equal to said fourth steel material of said gusset beam (40).
    [0007]
    7. Vehicle door assembly (10) according to any one of claims 3 to 6, characterized in that said second steel material of said intermediate frame members (283 and 284) is thicker than said first steel material of said side frame members (281 and 282), thicker than said third steel material of said intermediate vertical beam (38) and thicker than said fourth steel material of said gusset beam (40 ).
    [0008]
    Vehicle door assembly (10) according to any one of claims 1 to 7, characterized in that it further comprises a module extension (16) attached to said inner panel (12) so that said panel internal (12) is disposed between said external panel (14) and said module extension (16).
    [0009]
    9. Vehicle door assembly (10) according to claim 8, characterized by the fact that it also comprises a retractable window panel (21) disposed between said module extension (16) and said internal panel (12 ).
    [0010]
    10. Vehicle door assembly (10) according to any one of claims 1 to 9, characterized in that it further comprises a window frame (20) comprising an external window frame member (22) and a inner window frame member (24) attached to each other and to said inner panel (12).
    [0011]
    11. Vehicle door assembly (10) according to claim 10, characterized in that said external window frame member (22) includes, first, second and third separate parts (221, 222 and 223) integrally fixed to each other; wherein said second external window piece (222) is disposed between said first external window piece (221) and said third (223) external window piece; wherein said first external window piece (221) is made of a first external window steel material, said second external window piece (222) is made of a second external window steel material, and said third external window piece (223) is made of a third external window steel material; and wherein said first, second and third external window steel materials are different from each other.
    [0012]
    12. Vehicle door assembly (10) according to claim 11, characterized in that said second external window steel material is thicker than both said first external window steel material and said third steel material of external window.
    [0013]
    13. Vehicle door assembly (10) according to claim 11 or 12, characterized in that said internal window frame member (24) includes first and second separate parts (241 and 242) integrally fixed to one the other; wherein said first inner window piece (241) is made of a first inner window steel material and said second inner window piece (242) is made of a second inner window steel material; and wherein said first and second inner window steel materials are different from each other.
    [0014]
    Vehicle door assembly (10) according to claim 13, characterized in that said second inner window steel material is thicker than said first inner window steel material.
    [0015]
    15. Vehicle door assembly (10) according to claim 1, characterized by the fact that it further comprises spheres (17) of adhesive material arranged between said external panel (14) and said internal panel (12).
    [0016]
    16. Vehicle door assembly (10), according to claim 15, characterized by the fact that each of said horizontal upper and lower beams (30, 32) and said vertical front and rear beams (34, 36) has an open profile with a crown portion (33c, 35c and 37c) and a flange (33F, 35F and 37F) extending from said crown portion (33c, 35c and 37c) towards said outer panel ( 14) of said door assembly (10), wherein each of said flanges (33F, 35F and 37F) of said horizontal upper and lower beams (30, 32) and said vertical front and rear beams (34, 36) it is provided with a flap (33L, 35L and 35L) that extends from a distal end thereof, and in which said spheres (17) of adhesive material are disposed between an internal surface of said external panel (14) and said flaps (33L, 35L and 37L) of said inner panel (12).
    [0017]
    17. Method for manufacturing a vehicle door assembly (10) comprising an inner panel (12) in the form of a substantially rectangular frame portion (28) that has a continuous perimeter formed integrally by upper and lower horizontal beams ( 30, 32) interconnected by vertical front and rear beams (34, 36), characterized by the fact that it comprises the steps of: providing front and rear flat U-shaped steel sheets (52F and 52R) of a first steel material , each of said front and rear U-shaped steel blades (52F, 52R) comprising a cross portion (52FC, 52RC) and a pair of leg portions spaced from each other (52F1 and 52F2, 52R1 and 52R2) extending from said cross portion (52FC, 52RC); supplying upper and lower flat steel blades (52T and 54B) of a second steel material; non-releasably connecting each of said leg portions (52F1 and 52F2, 52R1 and 52R2) of each of said U-shaped steel sheets (52F, 52R) to a respective one of said top and bottom steel sheets (54T and 54B) so as to form a flat door perimeter frame gross (50); and pressing said door frame perimeter gross (50) into said frame portion (28) of said inner panel (12); said first steel material of said front and rear flat U-shaped steel blades (52F, 52R) being different from said second steel material of said top and bottom flat steel blades (54T and 54B); said frame portion (28) comprising opposite front and rear U-shaped frame members (281 and 282) fixed releasably to each other by upper and lower intermediate frame members (283 and 284) in order to forming said continuous perimeter; said side frame members (281 and 282) being made of said first steel material and said intermediate frame members (283 and 284) being made of said second steel material.
    [0018]
    18. Method for manufacturing said vehicle door assembly (10), according to claim 17, characterized by the fact that said second steel material of said intermediate frame members (283 and 284) is thicker than said first steel material of said side frame members (281 and 282).
    [0019]
    19. Method for the manufacture of said vehicle door assembly, according to claim 17 or 18, characterized by the fact that it further comprises the steps of: providing a flat steel sheet of a third steel material that is different from said second steel material of said intermediate board members (283 and 284); pressing said flat steel sheet into a single intermediate vertical beam (38); and securely fixing said intermediate vertical beam (38) to said intermediate frame members (283 and 284) of said frame portion (28) at distal ends thereof.
    [0020]
    20. Method for the manufacture of said vehicle door assembly (10), according to claim 19, characterized in that said first steel material of said side frame members (281 and 282) is different for the said third steel material of said intermediate vertical beam (38).
    [0021]
    21. Method for manufacturing said vehicle door assembly (10) according to either of claims 19 or 20, characterized in that said second steel material of said intermediate frame members (283 and 284) it is thicker than said first steel material of said side frame members (281 and 282) and thicker than said third steel material of said intermediate vertical beam (38).
    [0022]
    22. Method for the manufacture of said vehicle door assembly (10), according to any one of claims 19 or 20, characterized by the fact that it further comprises the steps of: supplying a flat sheet of rough steel of a quarter steel material which is different from said second steel material of said intermediate frame members (283 and 284); pressing said flat steel sheet into a single gusset beam (40); and securely fixing said gusset beam (40) to said front U-shaped side frame member (281) and to the upper intermediate frame member (283) at the distal ends thereof.
    [0023]
    23. Method for manufacturing said vehicle door assembly (10), according to claim 22, characterized in that said first steel material of said side frame members (281 and 282) is different from said fourth steel material of said gusset beam (40).
    [0024]
    24. Method for manufacturing said vehicle door assembly (10) according to claim 22 or 23, characterized in that said third steel material of said intermediate vertical beam (38) is equal to said fourth steel material of said gusset beam (40).
    [0025]
    25. Method for manufacturing said vehicle door assembly (10) according to any one of claims 22 to 24, characterized in that said second steel material of said intermediate frame members (283 and 284) is thicker than said first steel material of said side frame members (281 and 282), thicker than said third steel material of said intermediate vertical beam (38) and thicker than said fourth steel material of said gusseted beam (40).
    [0026]
    26. Method for manufacturing said vehicle door assembly (10), according to any one of claims 17 to 25, characterized in that it further comprises the steps of: providing an external door panel (14); and fixing said external door panel (14) to said internal panel (12).
    [0027]
    27. Method for the manufacture of said vehicle door assembly (10), according to claim 26, characterized by the fact that it further comprises the steps of: providing a module extension (16); and fixing said module extension (16) to said internal panel (12) so that said internal panel (12) is disposed between said external door panel (14) and said module extension (16).
    [0028]
    28. Method for the manufacture of said vehicle door assembly (10), according to claim 27, characterized by the fact that it further comprises the steps of: providing a window panel (21); retractably mounting said window panel (21) between said module extension (16) and said inner panel (12).
    [0029]
    29. Method for manufacturing said vehicle door assembly (10), according to any one of claims 17 to 28, characterized in that it further comprises the steps of: forming a single external window frame member (22) and a single internal window frame member () 24; securing said outer window frame member (22) and said inner window frame member (24) to each other to form a window frame (20); and fixing said window frame (20) to said inner panel (12).
    [0030]
    30. Method for the manufacture of said vehicle door assembly (10), according to claim 29, characterized in that the step of forming said window frame (20) comprises the steps of: supplying first, second and third flat sheets made of first, second and third external window steel materials, respectively; securely fixing said first, second and third flat sheets together so as to form a single outer window blank; and pressing said external window frame onto said single external window frame member (22); the first, second and third external window steel materials being different from each other.
    [0031]
    31. Method for the manufacture of said vehicle door assembly (10) according to claim 30, characterized in that said second external window steel material is thicker than both said first steel material of window external window and said third external window steel material.
    [0032]
    32. Method for manufacturing said vehicle door assembly (10) according to claim 30 or 31, characterized in that the step of forming said window frame (20) comprises the steps of: providing first and second flat blades made of first and second inner window steel materials, respectively; securely fixing said first and second flat blades together so as to form a single internal window blank; and pressing said inner window gross into said single inner window frame member (24); the first and second inner window steel materials being different from each other.
    [0033]
    33. Method for making said vehicle door assembly (10) according to claim 32, characterized in that said second inner window steel material is thicker than said first window steel material internal.
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    同族专利:
    公开号 | 公开日
    US9308577B2|2016-04-12|
    KR20140072146A|2014-06-12|
    EP2760687A1|2014-08-06|
    KR101947048B1|2019-02-12|
    ES2638141T3|2017-10-18|
    JP2014528376A|2014-10-27|
    MX344713B|2017-01-03|
    UA112663C2|2016-10-10|
    US20130088037A1|2013-04-11|
    IN2014DN03400A|2015-06-26|
    EP2760687B1|2017-06-14|
    US20150101193A1|2015-04-16|
    RU2014117631A|2015-11-10|
    HUE036293T2|2018-06-28|
    ZA201403034B|2015-05-27|
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    CN104066606A|2014-09-24|
    MX2014003866A|2014-10-17|
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    BR112014007461A2|2017-04-04|
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    JP6068480B2|2017-01-25|
    WO2013049801A1|2013-04-04|
    CN104066606B|2016-11-23|
    CA2850012C|2020-07-21|
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    KR102109428B1|2018-12-06|2020-05-12|현대자동차 주식회사|Jig apparatus for assembling aluminum door|
    法律状态:
    2018-12-11| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|
    2020-01-28| B06U| Preliminary requirement: requests with searches performed by other patent offices: suspension of the patent application procedure|
    2020-10-06| B09A| Decision: intention to grant|
    2021-01-05| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 01/10/2012, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US201161541568P| true| 2011-09-30|2011-09-30|
    US61/541,568|2011-09-30|
    PCT/US2012/058272|WO2013049801A1|2011-09-30|2012-10-01|Lightweight steel door for vehicle and method for manufacturing the same|
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