CN116568591A

CN116568591A - Vehicle body frame, vehicle body frame component member preform, method for manufacturing vehicle body frame component member, and vehicle body frame component member

Info

Publication number: CN116568591A
Application number: CN202180080075.3A
Authority: CN
Inventors: 奥斯卡·齐塔
Original assignee: Zeta Process Design Co ltd
Current assignee: Zeta Process Design Co ltd
Priority date: 2020-10-02
Filing date: 2021-10-01
Publication date: 2023-08-08
Also published as: PL438785A1

Abstract

The object of the invention is a vehicle side frame preform, a method for manufacturing a vehicle side frame from a vehicle side frame preform, and a vehicle side frame manufactured with the method. The object of the invention is also a vehicle floor element preform, a method of manufacturing a vehicle floor element from a vehicle floor element preform and a vehicle floor element manufactured with the method, and a vehicle floor system comprising such a vehicle floor element. The object of the invention is also a vehicle frame longitudinal member preform, a method of manufacturing a vehicle frame longitudinal member from a vehicle frame longitudinal member preform, and a vehicle frame longitudinal member manufactured with the method. The object of the invention is also a vehicle body frame formed by at least one vehicle side frame, at least one vehicle floor member and at least one vehicle frame longitudinal member. These objects of the invention are manufactured with a technique for causing deformation by using a pressurized fluid which is introduced through a valve element arranged on at least one preform wall into an airtight, empty space of the preform, which is formed by an inner wall and an outer wall connected to each other by corresponding seals.

Description

Vehicle body frame, vehicle body frame component member preform, method for manufacturing vehicle body frame component member, and vehicle body frame component member

The present invention relates to a vehicle body frame and its constituent members; in particular, the present invention relates to a vehicle side frame preform, a method for manufacturing a vehicle side frame, and a vehicle side frame particularly used as a structural member (as a load-bearing member) of a vehicle frame. The invention also relates to a vehicle floor component preform, a vehicle floor component manufacturing method, a vehicle floor component and a vehicle floor system, in particular as a structural component of a vehicle frame (as a carrier component), and a component for mounting a vehicle suspension and propulsion device. The present invention relates to a vehicle frame longitudinal component member preform, a method for manufacturing a vehicle frame side member, and a frame longitudinal member particularly useful as a structural member of a vehicle frame, which is a member that enhances vehicle rigidity and provides a controlled crumple zone of the vehicle. The invention is applicable to the automotive industry and in particular to the construction of one-piece body structures.

The dynamic development of electric vehicles places increasingly stringent requirements in relation to the individual structural components of the vehicle. One of the key requirements for electric vehicles is to keep the weight of the service low due to the relatively high weight of the power supply of the electric motor used in the vehicle. Structures that ensure low vehicle servicing weight, as well as desired vehicle rigidity and adequate protection for the occupants, include structures such as one-piece body types, sometimes referred to as "load-bearing chassis". The one-piece vehicle body has a low trim weight, while also having a fully designed controlled crumple zone that distributes forces acting on the body during a collision and ensures proper protection of the passenger compartment. In the one-piece vehicle body structure, the respective constituent members thereof (such as the pillar, the side sill, the longitudinal frame member, the cross member) are connected to each other by welding or pressure welding. The one-piece vehicle body is provided with all necessary connecting elements for mounting, in particular, steering and drive mechanisms and the like. An important structural component of an integrated body frame is the side frame, which extends along the side of the vehicle and is responsible for the rigidity of the structure and the safety of the body. Another important structural component of the one-piece body frame is a floor member, which is a supporting element of the vehicle suspension component and supports the necessary propulsion devices, thus taking care of the rigidity of the structure and the safety of the body. Another important structural member of the one-piece body frame is the frame longitudinal member, i.e., the longitudinal portion of the vehicle frame structure. The purpose of the frame longitudinal members is to increase the rigidity of the vehicle body and to partially absorb impact energy from the front or rear of the vehicle.

Document WO 2018115827 A1 discloses a vehicle comprising a load-bearing or semi-load-bearing body formed of composite material and forming the central body of the vehicle. Further, the vehicle body includes two support members mounted on the outside to distribute forces around the vehicle. The first and second support members are attached to each other to transfer force between the two support members, wherein the body or the support members or all of the components are provided with areas of increased strength, and the two externally mounted support members are configured to transfer force to the areas. The patent also discloses a support member as a hollow tubular component having a recess formed therein. The recess may accommodate additional stiffeners and foam cores. These support members may be made of metal, suitable fibre reinforced plastic, for example by moulding or 3D printing.

European patent EP 2895381 B1 discloses a motor vehicle body which comprises a lateral roof frame which is of load-bearing design and has an inner shell and an outer shell formed from sheet metal. The inner and outer shells are interconnected via two flanges, thereby enclosing a common cavity. Within the cavity is arranged a tube, which is a reinforcement for the lateral roof frame. The reinforcement tube is made of fiber reinforced plastic, which provides production advantages as it allows to form any shape and affects the cost of the manufacturing process.

Document DE 102005049781 B4 discloses a frame structure for a vehicle body, a truck, a ship or an aircraft, which frame structure has ring-shaped self-supporting frame elements which together form the frame structure. The ring elements are connected to each other and made of semi-finished products for transport, wherein the semi-finished products are made of various materials and/or have areas of different material thickness and/or areas of different cross-sectional area to match a specific desired load. The individual semifinished products are connected to each other, thereby forming an annular structural component. The connection may be made by press fitting and other joining methods known in the art. In the disclosed document, these semifinished products can be produced by bending or rolling.

European patent application EP 2729348 A1 discloses a substructure for a vehicle, which comprises elements for accommodating an energy storage module. These elements comprise at least two longitudinal members and at least two transverse members. Furthermore, the cited patent document discloses a motor vehicle comprising such a substructure and an electric motor and/or an internal combustion engine. The disclosed base structure provides improved battery protection in the event of a side impact without negatively impacting overall weight or cost. The element for receiving the energy storage modules has at least one deformation zone with defined deformation behavior between the energy storage modules.

A vehicle floor structure is known from US 8814255 B2, the main structure of which is a double-layer structure comprising two panels formed from a fibre-reinforced thermoplastic composite material. In the region including the double layer structure, each panel includes two continuous reinforcing structures having a convex opening cross-sectional shape, wherein recesses are provided at least two positions of the reinforcing structures. The panels are connected in such a way that the reinforcing structures of the respective panels intersect each other and that recesses provided in the reinforcing structures of the respective panels cooperate with each other.

The object of the US patent application US 2017001507 A1 is a underbody structure for a motor vehicle, which is configured to form a hybrid integral body with an upper body. The underbody structure provides a configurable platform for use in a variety of motor vehicle product lines to accommodate vehicles of various sizes having various upper bodies. The underbody structure includes a peripheral frame defining a battery cover and a body receiving a battery pack. The underbody structure also includes a front bumper constructed of cold rolled metal (such as aluminum). The front bumper has a generally tubular cross-sectional area and an arcuate shape. The front bumper is coupled to a pair of guide rails forming a so-called crash can. The underbody structure additionally includes frame transition sections that are complementary components that provide a narrowing connection between the left and right central frame sections.

European patent application EP 1671872 A1 discloses a side sill type vehicle body frame including a pair of side frames extending longitudinally on both left and right sides of the vehicle body and a plurality of cross members extending transversely between the side frames. The underbody frame of the vehicle is provided with a body reinforcement means attached to a mount on the side frame, wherein the reinforcement means extends in the lateral direction of the body frame and comprises means for generating a hydraulic damping force that acts against deformation in case of a collision.

Polish utility model PL 69477Y1 discloses a body frame longitudinal member, particularly for heavy vehicles and trailers. In its lower part, the profile of the longitudinal member of the body frame comprises two U-shaped chambers which are next to each other at the same height and which have openings in their bases, wherein the side walls of the U-shaped chambers are connected in their profile with the flat race base via a guide wall which is inclined at an angle to the race. Parallel to the two chambers, there is a side wall adjoining, which protrudes below the rim of the seat, and parallel to this side wall there is a reinforcing protrusion, forming an open chamber with a profiled recess in the side wall. Above the open chamber, in the upper part of the profile, there is a channel with a cylindrical cross section, which is open along a part of its periphery and is in turn surrounded by a closed chamber adjoining a closed rectangular chamber and a closed triangular chamber, respectively above the U-shaped chamber in the lower part of the profile.

European patent EP 3464033 B1 discloses a longitudinal member for a heavy goods vehicle structure comprising a front end intended to be oriented towards the front of the heavy goods vehicle structure, wherein the front end is provided with a hinge element for hingedly attaching the longitudinal member to the body of the heavy goods vehicle. The longitudinal member additionally comprises a rear end intended to be oriented towards the rear of the heavy goods vehicle, wherein the rear end comprises an attachment element for non-permanently attaching the longitudinal member to the body of the heavy goods vehicle. The product of the wall thickness of the front portion and the yield strength of the material of the front portion is greater than the product of the wall thickness of the rear portion and the yield strength of the material of the rear portion. As a result, the longitudinal member ensures energy absorption of the impact by deformation of the rear portion of the longitudinal member, so that the space in which the vehicle occupant sits is still protected by the front portion of the longitudinal member, which is substantially non-deformable during the impact.

European patent EP 2143621 B1 discloses a vehicle body reinforcing member manufactured by performing bending in which the bending direction is changed in a two-dimensional manner (in two planes), such as S-shaped bending, or performing bending in which the bending direction is changed in a three-dimensional manner (in three planes). The object of the cited patent is likewise a front frame side member as a reinforcement member of a motor vehicle body, and a side structure of a motor vehicle body, in particular a side structure of a motor vehicle body having a body a pillar, a body B pillar and a roof rail side member. The body reinforcement member is a single axial positioning element having a locally high-strength portion, an induction quenched under a high-frequency current, and a tubular body having a closed cross section. As a result, a reinforcing element having a low weight, high strength, excellent impact absorbing characteristics, and a reduced number of parts and thus reduced manufacturing costs is obtained.

The object of european patent EP 2691287 is a utility vehicle chassis and a method for manufacturing a profiled longitudinal beam of such a utility vehicle chassis. The utility vehicle chassis has at least one profile longitudinal beam with a longitudinal profile extending in the longitudinal direction of the profile longitudinal beam, which longitudinal profile is coated with an anti-corrosion layer and has a web, wherein the reinforcement plate is non-detachably fastened to at least a portion of the longitudinal profile. The longitudinal section bar of the section bar longitudinal beam is formed by sheet metal materials through a deformation process. The reinforcing plate is connected to the longitudinal profile only by a form fit or interference fit, without the use of welded joints or other joints to which heat is supplied.

The technical problem underlying the present invention is to provide a method for manufacturing a vehicle body frame component member comprising a vehicle side frame, a vehicle floor member and a vehicle frame longitudinal member which will allow the manufacture of said vehicle body frame component member for use as a vehicle integrated body having desired properties, in particular in terms of strength and weight of preparation, while maintaining a desired dimensional accuracy. It is desirable that the technical steps of the method for manufacturing a vehicle body frame component member be limited in number and be accomplished without the need for specialized personnel and complex equipment in order to directly provide the economic benefit of simplifying, less time consuming and therefore cheaper manufacturing of the vehicle body frame component member. It is also desirable that the method for manufacturing a body frame component member have the feature of low material consumption and allow for the manufacture of body frame component members having a wide range of geometric parameters, thereby allowing the geometry and strength of the body frame component member to be tailored to the remaining structural members of the vehicle's integrated body. It is also important to provide a method for manufacturing a vehicle body frame component member that will allow the shape of the vehicle body frame component member to be easily modified over a wide range of geometric parameters and without the need to rearrange the equipment used in the manufacturing process. The technical problem underlying the present invention is also to provide a vehicle body frame component having the characteristics and desired technical parameters for use in motor vehicles, in particular in vehicles provided with electric or hydrogen propulsion devices, including vehicle side frames, vehicle floor members and vehicle frame longitudinal members.

A first object of the invention is a vehicle side frame preform having a substantially annular structure in a side view thereof, the substantially annular structure defining an access opening for the vehicle, the vehicle side frame preform comprising a front pillar portion, a roof frame portion, a rear pillar portion and a door sill portion, characterized in that the vehicle side frame preform comprises an inner wall and an outer wall, which are made of sheet metal, arranged relative to each other while providing a gap, which forms a closed, empty interior space of the vehicle side frame preform, wherein a valve element is arranged on at least one of the walls.

Preferably, the vehicle side frame preform further comprises at least one central pillar portion extending between the roof frame portion and the threshold portion and separating an access opening of the vehicle.

Preferably, the vehicle side frame preform has inner wall regions and/or outer wall regions with an increased thickness of the metal sheet.

Preferably, the vehicle side frame preform has at least one inner pocket disposed in the gap between the inner wall and the outer wall.

Preferably, the inner bag is in fluid communication with the valve element.

Preferably, a filler is present in the inner bag.

Preferably, the filler is a one-component, two-component or three-component foam or non-newtonian fluid.

Preferably, the outer edge and/or the inner edge of the vehicle side frame preform is sealed with a seal, thereby forming a closed, airtight, empty interior space of the vehicle side frame preform.

Preferably, the seal is a fusion weld, a press weld, an adhesive layer, or a lap joint.

Preferably, the valve element is a pneumatic or hydraulic connection.

A second object of the present invention is a method for manufacturing a vehicle side frame, characterized in that the method comprises the steps of:

a) There is provided a vehicle side frame preform as defined in the first object of the invention,

b) Sealing the unattached edges of the vehicle side frame preform with a seal to form a closed, airtight, empty interior space of the vehicle side frame preform,

c) Pressurized fluid is introduced through the valve element into the interior space of the vehicle side frame preform to form a deformed vehicle side frame.

Preferably, the method for manufacturing a vehicle side frame comprises the additional steps of: pressurized fluid is introduced into the inner bag through the valve element.

Preferably, step c) is performed after introducing at least a portion of the vehicle side frame preform between the pressure plates such that the pressure plates are in contact with the walls of the vehicle side frame preform to introduce at least one flattened area on a portion of the vehicle side frame preform.

Preferably, during step c), forces are applied to the pressure plates in the direction of the vehicle side frame preform.

Preferably, step c) is performed by connecting a pressurized fluid source to the valve element.

Preferably, step b) is achieved by fusion welding, pressure welding, gluing or crimping.

Preferably, the fluid is air, water, oil, fluid concrete or fluid plastic.

Preferably, step c) is performed at room temperature or at an elevated temperature.

Preferably, the pressure of the fluid introduced into the vehicle side frame preform is at least 5 bar.

A third object of the invention is a vehicle side frame having a substantially annular structure in a side view thereof, which substantially annular structure defines an access opening of the vehicle, the vehicle side frame comprising a front pillar portion, a roof frame portion, a rear pillar portion and a door sill portion, characterized in that the vehicle side frame is deformed by a pressurized fluid introduced into its airtight, empty space, which space is formed by an inner wall and an outer wall connected to each other by a corresponding seal, wherein a valve element is arranged on at least one of the walls.

Preferably, the vehicle side frame further comprises at least one central pillar portion extending between the roof frame portion and the threshold portion and separating an access opening of the vehicle, wherein the central pillar portion is deformed by the pressurized fluid.

Preferably, the vehicle side frame has an inner wall region and/or an outer wall region, which regions have an increased thickness of the metal plate.

Preferably, the vehicle side frame has at least one inner pocket arranged in a space between the inner wall and the outer wall.

Preferably, the inner bag is in fluid communication with the valve element, and pressurized fluid introduced into the interior of the inner bag deforms the inner bag.

Preferably, a filler is present in the inner bag.

Preferably, the valve element is a pneumatic or hydraulic connection.

Preferably, the fluid is air, water, oil, fluid concrete or fluid plastic.

Preferably, the vehicle side frame has at least one flattened area on the inner wall and/or the outer wall.

A fourth object of the invention is a vehicle floor member preform having a substantially annular structure defining a storage opening in a top view thereof, the vehicle floor member preform comprising a front frame portion, a rear frame portion, a plurality of side frame portions, a front bumper portion extending from the front frame portion and a rear bumper portion extending from the rear frame portion, characterized in that the vehicle floor member preform comprises an inner wall and an outer wall, which are made of sheet metal, arranged with respect to each other while providing a gap forming a closed, empty interior space of the vehicle floor member preform, wherein a valve element is arranged on at least one of the walls.

Preferably, the vehicle floor member preform further comprises at least one frame longitudinal rib extending between the front frame portion and the rear frame portion and separating the storage opening.

Preferably, the vehicle floor member preform further comprises at least one frame transverse rib extending substantially perpendicular to the side frame portions.

Preferably, the frame longitudinal ribs and/or the frame transverse ribs are separate members from the generally annular structure of the vehicle floor member.

Preferably, the vehicle floor member preform further comprises at least one reinforcement pillar in the region of the front bumper portion and/or in the region of the rear bumper portion.

Preferably, the reinforcement column is a separate component from the front bumper portion and/or the rear bumper portion.

Preferably, the floor element preform has an inner wall region and/or an outer wall region, which regions have an increased thickness of the metal sheet.

Preferably, the floor element preform has an inner wall region and/or an outer wall region made of different materials.

Preferably, the vehicle floor member preform has at least one inner pocket disposed in the gap between the inner wall and the outer wall.

Preferably, the inner bag is in fluid communication with the valve element.

Preferably, a filler is present in the inner bag.

Preferably, the outer edge and/or the inner edge of the vehicle floor member preform is sealed with a seal, thereby forming a closed, airtight, empty interior space of the vehicle floor member preform.

Preferably, the valve element is a pneumatic or hydraulic connection.

A fifth object of the present invention is a method for manufacturing a vehicle floor member, characterized in that the method comprises the steps of:

a) There is provided a vehicle floor member preform as defined in the fourth object of the invention,

b) Sealing the unattached edge of the vehicle floor member preform with a seal to form a closed, airtight, empty interior space of the vehicle floor member preform,

c) Pressurized fluid is introduced through the valve element into the interior space of the vehicle floor member preform to form a deformed vehicle floor member.

Preferably, the method for manufacturing a vehicle floor member includes the additional steps of: pressurized fluid is introduced into the inner bag through the valve element.

Preferably, step c) is performed after introducing at least a portion of the vehicle floor member preform between the pressure plates such that the pressure plates are in contact with the walls of the vehicle floor member preform to introduce at least one flattened area on a portion of the vehicle floor member preform.

Preferably, during step c), forces are applied to the pressure plates in the direction of the vehicle floor member preform.

Preferably, the fluid is air, water, oil, fluid concrete, fluid plastic or flowable natural material.

Preferably, the pressure of the fluid introduced into the vehicle floor member preform is at least 2 bar.

A sixth object of the invention is a vehicle floor member having a substantially annular structure defining a storage opening in a top view thereof, the vehicle floor member comprising a front frame portion, a rear frame portion, a plurality of side frame portions, a front bumper portion extending from the front frame portion and a rear bumper portion extending from the rear frame portion, characterized in that the vehicle floor member is deformed by a pressurized fluid introduced into an airtight, empty space thereof, the space being formed by an inner wall and an outer wall connected to each other by corresponding seals, wherein a valve element is arranged on at least one of the walls.

Preferably, the vehicle floor member further comprises at least one frame longitudinal rib extending between the front frame portion and the rear frame portion and separating the storage opening, wherein preferably the frame longitudinal rib is deformed by the pressurized fluid.

Preferably, the vehicle floor member further comprises at least one frame transverse rib extending substantially perpendicular to the side frame portions, wherein preferably the pressurized fluid deforms the frame transverse rib.

Preferably, the frame longitudinal ribs and/or the frame transverse ribs are separate members from and connected to the generally annular structure of the vehicle floor member.

Preferably, the vehicle floor member further comprises at least one reinforcement column in the region of the front bumper portion and/or in the region of the rear bumper portion, wherein preferably the reinforcement column is deformed by the pressurized fluid.

Preferably, the reinforcement column is a separate component from and connected to the front and/or rear bumper portions.

Preferably, the vehicle floor member has an inner wall region and/or an outer wall region, which regions have an increased thickness of the metal plate.

Preferably, the vehicle floor member has an inner wall region and/or an outer wall region made of different materials.

Preferably, the vehicle floor member has at least one inner bag disposed in a space between the inner wall and the outer wall.

Preferably, a filler is present in the inner bag.

Preferably, the valve element is a pneumatic or hydraulic connection.

Preferably, the vehicle floor member has at least one flattened area on the inner wall and/or the outer wall.

A seventh object of the invention is a vehicle flooring system, characterized in that the vehicle flooring system comprises at least two vehicle flooring members as defined in the sixth object of the invention, wherein the at least two vehicle flooring members are arranged one above the other.

Preferably, the vehicle flooring system has at least one side panel that connects with a corresponding edge of each vehicle flooring member and ensures that the vehicle flooring members maintain a defined distance relative to each other.

Preferably, the side panels are located in the region of the side frame portions, the front bumper portion and/or the rear bumper portion.

Preferably, the side panel is a member deformed by a pressurized fluid introduced into the interior of the inner bag.

An eighth object of the invention is a vehicle frame longitudinal member preform having a longitudinal structure in a side view thereof, the longitudinal structure comprising a front portion oriented towards the front of the vehicle frame and a central portion arranged in the central portion of the vehicle frame, characterized in that the vehicle frame longitudinal member preform comprises an inner wall and an outer wall, which are made of sheet metal, are arranged relative to each other while providing a gap, which forms a closed, empty interior space of the vehicle frame longitudinal member preform, wherein a valve element is arranged on at least one of the walls.

Preferably, the vehicle frame longitudinal member preform further comprises a rear portion oriented towards the rear of the vehicle frame.

Preferably, the central portion is offset towards the bottom of the vehicle frame relative to the front portion.

Preferably, the front portion and/or the rear portion comprises an end loop structure.

Preferably, the transition region between the front portion and the central portion comprises a transition annular structure.

Preferably, the central portion comprises a central annular structure.

Preferably, the central portion includes at least one stiffening rib extending through an opening defined by the central annular structure.

Preferably, the vehicle frame longitudinal member preform has inner wall regions and/or outer wall regions with an increased thickness of the metal sheet.

Preferably, the vehicle frame longitudinal member preform has an inner wall region and/or an outer wall region made of different materials.

Preferably, the outer edge and/or the inner edge of the vehicle frame longitudinal member preform is sealed with a seal, thereby forming a closed, airtight, empty interior space of the vehicle frame longitudinal member preform.

A ninth object of the present invention is a method for manufacturing a vehicle frame longitudinal member, characterized in that the method comprises the steps of:

a) There is provided a vehicle frame longitudinal member preform as defined in the eighth object of the invention,

b) Sealing the unattached edge of the vehicle frame longitudinal member preform with a seal to form a closed, airtight, empty interior space of the vehicle frame longitudinal member preform,

c) Pressurized fluid is introduced through the valve element into the interior space of the vehicle frame longitudinal member preform to form a deformed vehicle frame longitudinal member.

Preferably, step c) is performed after introducing at least a portion of the vehicle frame longitudinal member preform between the pressure plates such that the pressure plates are in contact with the walls of the vehicle frame longitudinal member preform to introduce at least one flattened area on a portion of the vehicle frame longitudinal member preform.

Preferably, during step c), forces are applied to the pressure plates in the direction of the vehicle frame longitudinal member preform.

A tenth object of the invention is a vehicle frame longitudinal member having a longitudinal structure in its side view, comprising a front portion oriented towards the front of the vehicle frame and a central portion arranged in the central portion of the vehicle frame, characterized in that the vehicle frame longitudinal member is deformed by a pressurized fluid introduced into its airtight, empty space, which space is formed by an inner wall and an outer wall connected to each other by a corresponding seal, wherein a valve element is arranged on at least one of these walls.

Preferably, the vehicle frame longitudinal member further comprises a rear portion oriented towards the rear of the vehicle frame.

Preferably, the central portion comprises a central annular structure.

Preferably, the vehicle frame longitudinal member has an inner wall region and/or an outer wall region, which regions have an increased thickness of the metal plate.

Preferably, the vehicle frame longitudinal member has an inner wall region and/or an outer wall region made of different materials.

Preferably, the vehicle frame longitudinal member has at least one flattened area on the inner wall and/or the outer wall.

An eleventh object of the present invention is a vehicle body frame comprising constituent members connected to each other, characterized in that the constituent members are at least one side frame as defined in the third object of the present invention, at least one floor member as defined in the sixth object of the present invention, and at least one frame longitudinal member as defined in the tenth object of the present invention.

It should be emphasized that the features set forth in the preferred embodiments of the present invention can be freely combined with each other, unless specifically stated otherwise. The examples presented below are only illustrative of the purpose of the invention and are not intended to limit the scope of the invention, which is defined by the appended patent claims.

The method for manufacturing a vehicle body frame component member according to the present invention allows manufacturing vehicle body frame component members including vehicle side frames, vehicle floor members, and vehicle frame longitudinal members having desired characteristics particularly in terms of forming controlled crumple zones, rigidity and strength of a specific vehicle body frame component member, and reducing the weight of the service. In particular, since relatively thin metal plates are widely used in the manufacture of vehicle body frame component members, the vehicle body frame component members manufactured with the method according to the present invention allow for a significant reduction in the weight of the service, compared to classical solutions known in the art. Furthermore, the method for manufacturing a vehicle body frame constituent member according to the present invention is realized by using a less complex work, which translates into economic efficiency and significantly simplified manufacturing process of the vehicle body frame constituent member. The small number of seals improves the speed of the body frame component manufacturing process and reduces labor intensity. Furthermore, the production of the body frame component member as a structural member of the vehicle body in one piece allows the parameters of the produced body frame component member and thus of the final vehicle body in one piece to be modified over a wide range, in particular in terms of its final geometry, the strength of the individual zones of the body frame component member, the formation of controlled collapse zones, and the rigidity of the structure, on the basis of the introduction of a pressurized fluid into the hermetically closed interior space of the body frame component member preform.

The solution according to the invention has been shown in the following embodiments and is illustrated in the accompanying drawings, in which:

FIG. 1 is an isometric view of a vehicle integral body frame using two vehicle side frames according to one of the embodiments of the invention;

FIG. 2 is a side view of a vehicle side frame preform according to one embodiment of the invention;

FIG. 3 is a side view of a side frame according to another embodiment of the invention;

FIG. 4 is a cross-sectional view of a vehicle side frame preform during one of the steps of a method for manufacturing a vehicle side frame according to one embodiment of the invention;

FIG. 5 is a cross-sectional view of a vehicle side frame preform during one of the steps of a method for manufacturing a vehicle side frame according to another embodiment of the invention;

FIG. 6 is a cross-sectional view of a vehicle side frame according to an embodiment of the invention;

FIG. 7 is a cross-sectional view of a vehicle side frame according to an embodiment of the invention;

FIG. 8 is a side view of a vehicle side frame according to another embodiment of the invention, without an outer wall and showing the internal structure of the vehicle side frame;

FIG. 9 is a cross-sectional view of the vehicle side frame of FIG. 8;

FIG. 10 is a side view of a side frame according to another embodiment of the present invention, without an outer wall and showing the internal structure of the vehicle side frame;

FIG. 11 is a cross-sectional view of the vehicle side frame of FIG. 10;

FIG. 12 is a side view of a side frame according to another embodiment of the present invention, without an outer wall and showing the internal structure of the vehicle side frame;

FIG. 13 is a cross-sectional view of the vehicle side frame of FIG. 12;

fig. 14 is a side view of a vehicle side frame manufactured with the prior art, in which evaluation conditions for strength parameters of the following form are indicated: a) Compression along a vertical axis Z, B) compression along a horizontal axis X;

fig. 15 is a side view of a vehicle side frame according to one embodiment of the invention, in which evaluation conditions for strength parameters of the following form are indicated: a) Compression along a vertical axis Z, B) compression along a horizontal axis X;

fig. 16 is a side view of a vehicle side frame known in the art, wherein evaluation conditions for the following form of strength parameters are indicated: a) Compression along a vertical axis Z, B) compression along a horizontal axis X;

FIG. 17 is an isometric view of a vehicle integral body frame using a vehicle floor member according to one of the embodiments of the invention;

FIG. 18 is an isometric view of a vehicle floor member according to an embodiment of the invention;

FIGS. 19-28 are top views of a vehicle floor member preform according to further embodiments of the present invention;

Fig. 29-31 are isometric views of a vehicle flooring system according to a further embodiment of the present invention;

FIGS. 32A-B are cross-sectional views of a vehicle floor member according to an embodiment of the invention;

FIG. 33 is a cross-sectional view of a vehicle floor member according to an embodiment of the invention;

FIG. 34 is a cross-sectional view of the vehicle floor member of FIG. 27;

FIG. 35 is a cross-sectional view of the vehicle floor member of FIG. 26;

FIGS. 36 and 37 are displacement diagrams for a floor member according to the present invention;

FIGS. 38 and 39 are displacement diagrams for floor members manufactured by the prior art;

FIG. 40 is an isometric view of a vehicle integrated body frame having a vehicle frame longitudinal member according to one embodiment of the invention;

FIG. 41 is a side view of a vehicle frame longitudinal member preform according to an embodiment of the invention;

FIG. 42 is a side view of a vehicle frame longitudinal member according to another embodiment of the invention;

FIG. 43 is an isometric view of a frame longitudinal member according to an embodiment of the invention installed in a vehicle integral body frame;

FIG. 44 is a cross-sectional view of a vehicle frame longitudinal member according to an embodiment of the invention;

FIG. 45 is a side view of a vehicle frame longitudinal member preform according to another embodiment of the invention;

FIG. 46 is a side view of a vehicle frame longitudinal member according to another embodiment of the invention;

FIG. 47 is an isometric view of a vehicle frame longitudinal member according to another embodiment of the invention installed in a vehicle integrated body frame;

FIG. 48 is a cross-sectional view of a vehicle frame longitudinal member according to another embodiment of the invention;

FIG. 49 is a side view of a vehicle frame longitudinal member preform according to another embodiment of the present invention;

FIG. 50 is a side view of a vehicle frame longitudinal member according to another embodiment of the invention;

FIG. 51 is an isometric view of a vehicle frame longitudinal member according to another embodiment of the invention installed in a vehicle integrated body frame;

FIG. 52 is a cross-sectional view of a vehicle frame longitudinal member according to another embodiment of the invention;

FIG. 53 is a side view of a vehicle frame longitudinal member preform according to another embodiment of the present invention;

fig. 54 and 55 are side views of a vehicle frame longitudinal member according to another embodiment of the invention;

FIG. 56 is an isometric view of a vehicle frame longitudinal member according to another embodiment of the invention installed in a vehicle integrated body frame;

FIG. 57 is a cross-sectional view of a vehicle frame longitudinal member according to another embodiment of the invention;

FIG. 58 is an isometric view of a comparative frame model based on a vehicle frame longitudinal member known in the art;

FIG. 59 is an isometric view of a frame model based on a vehicle frame longitudinal member according to one embodiment of the invention;

FIG. 60 is an isometric view of the results of a numerical simulation showing the stress profile of the structure under a torsion test;

fig. 61 is an isometric view of a body frame according to an embodiment of the invention.

Example 1

Fig. 1 shows an isometric view of a vehicle integrated body frame using two vehicle side frames according to a first embodiment of the invention. A first embodiment of the invention, a vehicle side frame preform, is shown in side view in fig. 2.

As depicted in fig. 2, the vehicle side frame preform resembles the structure of an irregularly shaped annular structure. The vehicle side frame preform includes an access opening for the vehicle, as best shown in the isometric view of the vehicle body in one piece in fig. 1.

The vehicle side frame preform shown in fig. 2 includes a front pillar portion 1, a roof frame portion 2, a rear pillar portion 3, and a rocker portion 4. The above-mentioned parts of the vehicle side frame preform are connected to each other and form an integral part made of a metal plate, such as a steel plate, which defines the inner wall 6 and the outer wall 7. In this embodiment, the metal sheet does not have a uniform thickness over the entire surface area of the vehicle side frame preform, but rather has regions of differing thickness that are connected to one another and form a "stitched" structure.

As shown in fig. 2, the side frame preform is composed of three regions of material sheets (stainless steel sheets in this embodiment) having different thicknesses, which are schematically represented by corresponding cross-sectional lines. In this embodiment, the region having the first thickness of 1.2mm is indicated by a horizontal line and includes the lower section of the front pillar portion 1, the region having the second thickness of 1.0mm is indicated by a diagonal line and includes the lower section of the rear pillar portion 3 and the rocker portion 4, and the region having the third thickness of 0.8mm is indicated by a vertical line and includes the upper section of the front pillar portion 1, the roof frame portion 2 and the upper section of the rear pillar portion 3.

As a result, the inner wall 6 and the outer wall 7 are metal plates having different thicknesses in respective portions of the vehicle side frames (and corresponding vehicle side frame preforms). Due to the use of the spliced structure, the final vehicle side frame is given the desired functional characteristics, manifested by increased strength and rigidity in the region with increased plate thickness. Importantly, the structure of the inner wall 6 and the outer wall 7 is an integrated structure comprising regions of smaller and larger thickness of the metal sheet. The inner wall 6 and/or the outer wall 7 of the areas of different thickness may be obtained by any method known in the art, including, in a non-limiting way, selective press forming, rolling and joining of plates of different thickness, for example by welding.

However, it should be emphasized that the thickness of the plates and their variability in different regions of the vehicle side frame preform according to the present invention is not limiting to the scope of the invention, and that in alternative embodiments of the present invention, metallic plates having different thicknesses and made of different materials, as well as "stitched" structures having different geometries and thicknesses, and a plurality of regions having different thicknesses, may be used. The concepts of the inner wall 6 and the outer wall 7 are conventional and are intended to represent the inside and outside, respectively, of a vehicle in which the vehicle side frame of the present invention is used. The inner wall 6 and the outer wall 7 are arranged aligned (in plan) with respect to each other while providing a gap that forms a closed, empty interior space of the vehicle side frame preform. A valve element 8 is arranged on one of the walls 6, 7, which valve element allows fluid communication with the interior space formed between the walls 6, 7 of the vehicle side frame preform.

The valve element 8 is a pneumatic or hydraulic connection and allows for leak-proof fastening of a supply conduit from an external pressurized fluid source. In some embodiments of the invention, the valve element 8 may be a valve, in particular a check valve. The position of the valve element 8 is not a limitation on the scope of the present invention, and thus the valve element 8 may be arranged at any position on the metal plate, provided that connection with the inner space of the vehicle side frame preform is allowed.

In this embodiment, the outer and inner edges of the side frame preform (from the side of the access opening) are sealed with a seal 12, thereby forming a closed, airtight, empty interior space of the vehicle side frame preform.

After the walls 6, 7 of the vehicle side frame preform have been mated with each other, sealing is performed on the edges of the metal plates forming these walls. In this embodiment, sealing is thus performed on all circumferential edges of the mating walls 6, 7 of the vehicle side frame preform. In this embodiment, the sealing is performed by welding the corresponding edges together, in particular to form a circumferential weld. By sealing all the above edges, a leak-proof, airtight interior space is formed in the vehicle side frame preform. In this case, the type of the seal 12 is not a limitation on the scope of the present invention, and any type of seal 12 may be used in alternative embodiments as long as a leak-proof interior space is formed in the vehicle side frame preform, for example, by pressure welding, soldering, gluing, bending, or pressing.

A method for manufacturing a vehicle side frame according to one of the embodiments of the invention comprises the step of providing a vehicle side frame preform as defined in this embodiment. In the event that the vehicle side frame preform is provided without all of its peripheral edges being joined and sealed, the next step includes sealing the unconnected edges of the vehicle side frame preform with the seal 12 to form a closed, airtight, empty interior space of the vehicle side frame preform. As mentioned above, the seal 12 may be implemented in any known manner that ensures that a leak-proof interior space is formed.

In a next step, an external pressurized fluid source is connected to the valve element 8 through a supply conduit. In this embodiment, the fluid is air, the pressurized fluid source is a compressor, and the supply conduit forms a pneumatic connection with the valve element 8. The type of external pressurized fluid source and connection equipment is not limiting to the scope of the invention and in alternative embodiments, fluids may be used with connection equipment and pressurized fluid sources suitable for such fluids in the form of water, fluid cement, engine oil, fluid plastics such as single component, two component or three component foams (e.g., flex140 type), and the like. The less compressible the fluid, the more controlled the deformation conditions of the vehicle side frame preform.

In a further step of the method according to the invention for producing a vehicle side frame, a fluid under defined pressure is delivered to the sealed interior space of the vehicle side frame preform. A technique for introducing a pressurized fluid into a closed, sealed chamber element made of sheet metal to deform it and provide them with a final form is known in particular from patent application EP 2110189 A1. As a result of the pressurized fluid being delivered to the interior space of the vehicle side frame preform, the walls 6, 7 of the vehicle side frame preform deform, as best shown in fig. 7, which shows a cross section of a vehicle side frame manufactured from the vehicle side frame preform. As can be observed, the walls 6, 7 of the vehicle side frame preform are significantly deformed. It is important that the vehicle side frame according to the present embodiment of the invention has different geometric dimensions in the front pillar portion 1, the roof frame portion 2, the rear pillar portion 3, and the rocker portion 4. The choice of these geometries depends on the requirements used with respect to the safety parameters (i.e. the rigidity and strength of the structure, and the formation of controlled crumple zones) and the geometry of the vehicle body structure. These geometries can be freely changed as desired and tailored to a particular application.

It should be noted that while the introduction of the pressurized fluid into the interior space of the vehicle side frame preform is performed under cold technology (i.e., room temperature), this is not a limitation on the scope of the invention, and in alternative embodiments this process may be performed at elevated or elevated temperatures.

In one embodiment of the invention, the step of introducing the pressurized fluid is performed with the following process parameters:

process temperature: 20 c,

-working pressure: 5 bar of the total weight of the product,

deformation time: for 1 minute until the pressure in the vehicle side frame preform is equalized,

pressure retention time: for a period of 30 seconds,

total deformation time: 1.5 minutes.

Example 2

Another embodiment of the invention is shown in a side view in fig. 3, which shows a vehicle side frame.

In general, the vehicle side frame preform and the vehicle side frame manufactured therefrom are substantially similar to the structure of the vehicle side frame preform and the structure of the vehicle side frame shown in embodiment 1, and thus, for the sake of clarity of the present disclosure, description of similar structural elements will not be repeated.

It is important that the vehicle side frame (and corresponding vehicle side frame preform) shown in fig. 3 have flattened areas 9 on the inner wall 6 and the outer wall 7, wherein the flattened areas 9 have a substantially flat outer surface. The flattened area 9 allows additional adjustment of the technical parameters of the respective vehicle side frame part and is also a mounting area for additional final equipment of the vehicle.

The flattened area 9 may be obtained by using a method for manufacturing a vehicle side frame according to another embodiment of the present invention. Unlike the method for manufacturing a vehicle side frame shown in embodiment 1, in the method for manufacturing a side frame of the present embodiment, before the step of introducing the pressurized fluid into the inner space of the vehicle side frame preform, the vehicle side frame preform is placed between the pressure plates 13 such that the pressure plates 13 are in contact with the walls 6, 7 of the vehicle side frame preform, as shown in fig. 4. The pressure plate 13 may be a working element of a mechanical press. In this case, a controlled force can be applied to the pressure plate 13, in particular in the direction towards the vehicle-side frame preform. The vehicle side frame preform is held between the pressure plates 13 during the step of delivering pressurized fluid into the sealed interior space of the vehicle side frame preform. As a result, the vehicle side frame part manufactured in this way has flattened areas 9 in the desired vehicle side frame areas where the lining of the pressure plate 13 is applied. The section of fig. 6 shows a vehicle side frame with a region deformed in a free manner (without the pressure plate 13-on the left) and with a region deformed by the use of the pressure plate 13 with the flattened region 9 (on the right). This manufacturing method is implemented in the system shown in fig. 5, wherein one (left) vehicle side frame part is not in contact with the inner lining of the pressure plate 13 and can be deformed in a free manner, while the second (right) vehicle side frame part comprises walls in contact with the pressure plate 13. Thus, it is possible to provide a mounting area for the vehicle functional equipment for the desired location and to locally modify the technical properties of the vehicle side frame (such as the rigidity, strength of the structure) or to form a controlled crumple zone. Further, fig. 7 shows a cross section of a vehicle side frame with areas deformed in a free manner (without the use of pressure plates 13), the areas having different geometries (including different wall 6, 7 thicknesses) and also having different vehicle side frame area thicknesses after deformation.

Example 3

Another embodiment of the invention is shown in fig. 8, which shows a side view of the side frame without the outer wall 7 and shows the internal structure of the vehicle side frame.

In general, the vehicle side frame and the corresponding vehicle side frame preform are substantially similar in structure to those of the side frame and the vehicle side frame preform shown in embodiment 1, except that the vehicle side frame of the present embodiment additionally includes a center pillar portion 5 extending between the roof frame portion 2 and the threshold portion 4 and separating an access opening of the vehicle. The inner wall 6 and the outer wall 7 are integral single sheets of metal material which also comprise the area where the central column portion 5 is present. In side view, the vehicle side frame according to the present embodiment is also a ring-shaped structure having a different spatial shape depending on the planned application.

As depicted in fig. 8, unlike the vehicle side frame preform and corresponding vehicle side frame of embodiment 1, the vehicle side frame according to this embodiment includes additional internal structure in the form of an internal pocket 10. An inner bag 10 is arranged in the gap between the inner wall 6 and the outer wall 7, as best shown in the cross section of fig. 9. The inner bag 10 is a leak-proof, airtight structure in fluid communication with a valve element 8 that passes through the inner wall 6 or the outer wall 7 of the vehicle side frame, while the inner space of the vehicle side frame itself remains sealed. The inner bag 10 may be formed similarly to the side frame preform, i.e. from sheet metal connected to each other and sealed on the edges. In alternative embodiments, the inner bag 10 may be formed of other materials that provide an airtight seal to the container formed therein and include, in a non-limiting manner, a textile material.

The embodiment of the vehicle side frame shown in fig. 8 shows an inner bag 10 comprising four areas, wherein a first area of the inner bag 10 is located in the lower section of the front pillar portion 1, a second area of the inner bag 10 is located in the area of the threshold portion 4, a third area of the inner bag 10 is located in the lower section of the center pillar portion 5, and a fourth area of the inner bag 10 is located in the lower section of the rear pillar portion 3.

The inner bag 10 used in the vehicle side frame produces different results depending on its purpose. In this embodiment, the inner bag 10 is made of carbon steel plate, wherein the entire structure of the vehicle side frame is made of stainless steel plate. Carbon steel has higher hardness and strength than stainless steel, and thus the inner bag 10 made of carbon steel is an element that increases the strength of the vehicle side frame to provide it with desired technical characteristics. Furthermore, after the vehicle side frame has been formed (by deforming the preform), the inner bag 10 is deformed by the fluid (air) introduced into its airtight inner space, allowing additional local deformation to be created in the already formed vehicle side frame and allowing the geometry of the vehicle side frame to be adjusted to the desired shape.

In another embodiment, as shown in fig. 10 and 11, the inner bag 10 has no portion comprising the lower segment of the central column portion 5 and is made of a textile material (e.g. kevlar) forming a compartment in which the filling 11 is present. In this embodiment, the filler 11 is a non-newtonian fluid that allows for the formation of a substantially tuned damping region. The inner bag 10 with the non-newtonian fluid may be a separate structure that is introduced into the vehicle side frame preform, or the inner bag 10 may be filled with the non-newtonian fluid after the vehicle side frame has been formed. In the latter case, the inner bag 10 requires a valve element 8 for introducing the filling 11.

Importantly, the type of filler 11 present in the inner bag 10 is not limited to non-newtonian fluids, and in alternative embodiments, the filler 11 may be such that desired technical characteristics (e.g., sound insulation levels) are ensured, and may include one-component, two-component, or three-component foams.

Example 4

Another embodiment of the present invention is shown in fig. 12 (which shows a side view of the vehicle side frame) and fig. 13 (which shows a cross section of the vehicle side frame of fig. 12).

In general, the vehicle side frame and the corresponding vehicle side frame preform are substantially similar in structure to those of the side frame and the vehicle side frame preform shown in embodiment 1, except that the vehicle side frame of the present embodiment additionally includes two center pillar portions 5 extending between the roof frame portion 2 and the threshold portion 4 and separating the access opening of the vehicle. The inner wall 6 and the outer wall 7 are integral single sheets of metal material which also comprise the area where the central column portion 5 is present. In side view, the vehicle side frame according to the present embodiment is also a ring-shaped structure having a different spatial shape depending on the planned application.

In the embodiment shown in fig. 12 and 13, the vehicle side frame comprises two inner bags 10 in fluid communication with the valve element 8. The front inner bag 10 is located in the lower section of the front pillar portion 1 and in the front section of the rocker portion 4, while the rear inner bag 10 is located in the rear section of the rocker portion 4 and extends through the area of the rear central pillar portion 5 and through the rear pillar portion 3.

In this embodiment, both inner bags 10 include filler in the form of a sound insulating foam to provide the desired sound insulating properties and increase the strength parameters for the vehicle side frames.

Example 5

The vehicle side frame manufactured using the method according to the present invention was subjected to a comparative test (based on numerical calculation) with the vehicle side frame manufactured using the conventional technique. Fig. 14 is a side view of a vehicle side frame manufactured with the prior art, in which evaluation conditions for strength parameters of the following form are indicated: a) Compression along the vertical axis Z, B) compression along the horizontal axis X. The geometry of the conventional side frames corresponds to the geometry of the side frames of the present invention (shown for reference in fig. 15A-B).

The intensity parameters (expressed in N/mm) in the form of compression along the vertical axis Z and the horizontal axis X are evaluated. In the case of the conventional frame, tests were carried out on two embodiments based on a tubular profile of diameter 32mm and material thickness 1.5mm from which the individual constituent members of the side frame are made and on a rectangular profile of dimension 45mm x 20mm and material thickness 1.2 mm. The evaluation results are compared with the corresponding strength parameters of the side frames according to the invention made of sheet material with a thickness of 0.8 mm. The calculated intensity parameters are presented in table 1.

TABLE 1 comparison of side frame Strength parameters

As can be seen from table 1, the side frame according to the present invention is lighter than the side frame manufactured by conventional techniques considering the tubular profile and the rectangular profile. The side frames of the present invention (made of 0.8mm thick plates) also exhibit higher compressive stiffness parameters on the vertical axis Z and horizontal axis X.

Similar comparative tests (based on numerical calculations) were performed on the vehicle side frames made by the method of the present invention with the vehicle side frames known in the art, namely reynolds Twizy (model 45 in 2015). In this case, the side frames of the present invention are made of 1.2mm thick plates, the side frames of the prior art reflecting the geometry and configuration of the side frames known from reynolds Twizy (fig. 16). The calculated intensity parameters are presented in table 2.

TABLE 2 comparison of side frame strength parameters

As can be seen from table 2, the side frame according to the invention is lighter than a side frame corresponding to a vehicle frame known from the prior art. The side frames of the present invention (made of 1.2mm thick plates) also exhibit higher compressive stiffness parameters on the vertical axis Z and horizontal axis X.

Example 6

Fig. 17 shows an isometric view of a vehicle integral body frame using a vehicle floor member according to an embodiment of the invention. An embodiment of the present invention is shown in top view in fig. 19 as a vehicle floor member preform and in isometric view in fig. 18 as a floor member manufactured from the vehicle floor member preform.

As depicted in fig. 19, the vehicle floor member preform is a structure similar to a ring-shaped structure in its plan view, which is made of a front frame portion 101, an oppositely disposed rear frame portion 102, and two side frame portions 103 extending between the front frame portion 101 and the rear frame portion 102. The annular structure so formed defines a storage opening that is typical of the locations for storage of electric vehicle batteries in the final implementation of the electric vehicle. As can be seen in fig. 19, the front bumper portion 104 extends from the front frame portion 101, and the rear bumper portion 105 extends from the rear frame portion 102. In this embodiment, the front bumper portion 104 and the rear bumper portion 105 are each of a ring-shaped structure defining a rectangular internal opening. Although in this embodiment, the front bumper portion 104 and the rear bumper portion 105 are identical in their construction and geometry, this is not a limitation on the scope of the invention, and in alternative embodiments, both the front bumper portion 104 and the rear bumper portion 105 may have different constructions.

The above-mentioned components of the vehicle floor member preform are connected to each other and form an integral part made of a metal plate, such as a steel plate, defining an inner wall 106 and an outer wall 107 (see, for example, fig. 33, which is a longitudinal section of this embodiment of the vehicle floor member).

However, it should be emphasized that the plate thickness of the vehicle floor member preform is not a limitation on the scope of the invention, and that in alternative embodiments of the invention, metal plates having different thicknesses and made of different materials may be used. The concepts of the inner wall 106 and the outer wall 107 are conventional and are intended to represent the inside and outside, respectively, of a vehicle in which the vehicle floor member of the present invention is used. The inner wall 106 and the outer wall 107 are arranged in alignment (in plan) with respect to each other while providing a gap that forms a closed, empty interior space of the vehicle floor member preform. A valve element 108 is arranged on one of the walls 106, 107, which valve element allows fluid communication with the interior space formed between the walls 106, 107 of the vehicle floor member preform.

The valve element 108 is a pneumatic or hydraulic connection and allows for leak-proof fastening of a supply conduit from an external pressurized fluid source. In some embodiments of the present invention, the valve element 108 may be a valve, particularly a check valve. The location of the valve element 108 is not limiting to the scope of the invention, and thus the valve element 108 may be disposed in any location on the sheet metal provided that connection with the interior space of the vehicle floor member preform is permitted.

In this embodiment, the outer and inner edges (from the storage opening side) of the floor member preform are sealed with a seal 112, thereby forming a closed, airtight, empty interior space of the vehicle floor member preform.

After the walls 106, 107 of the vehicle floor member preform have been mated with each other, sealing is performed on the edges of the metal sheets forming these walls. In this embodiment, sealing is thus performed on all circumferential edges of the mating walls 106, 107 of the vehicle floor member preform. In this embodiment, the sealing is performed by welding the corresponding edges together, in particular to form a circumferential weld. By sealing all of the above edges, a leak-proof, airtight interior space is formed in the vehicle floor member preform. In this case, the type of seal 112 is not a limitation on the scope of the present invention, and any type of seal 112 may be used in alternative embodiments, so long as a leak-proof interior space is formed in the vehicle floor member preform, for example, by pressure welding, soldering, gluing, bending, or pressing.

A method for manufacturing a vehicle floor member according to one of the embodiments of the invention includes the step of providing a vehicle floor member preform as defined in the present embodiment. In the event that the vehicle floor member preform is provided without connecting and sealing all of its peripheral edges, the next step includes sealing the unconnected edges of the vehicle floor member preform with the seal 112 to form a closed, airtight, empty interior space of the vehicle floor member preform. As mentioned above, the seal 112 may be implemented in any known manner that ensures that a leak-proof interior space is formed.

In a next step, an external pressurized fluid source is connected to the valve element 108 through a supply conduit. In this embodiment, the fluid is air, the pressurized fluid source is a compressor, and the supply conduit forms a pneumatic connection with the valve element 108. The type of external pressurized fluid source and connection equipment is not limiting to the scope of the invention and in alternative embodiments, fluids may be used with connection equipment and pressurized fluid sources suitable for such fluids in the form of water, fluid cement, engine oil, fluid plastics such as one-component, two-component or three-component foams (e.g., flex140 type), flowable natural materials such as liquid rubber, and the like. The less compressible the fluid, the more controlled the deformation conditions of the vehicle floor member preform.

In a further step of the method for manufacturing a vehicle floor member according to the invention, a fluid under defined pressure is delivered to the sealed interior space of the vehicle floor member preform. A technique for introducing a pressurized fluid into a closed, sealed chamber element made of sheet metal to deform it and provide them with a final form is known in particular from patent application EP 2110189 A1. As a result of the pressurized fluid being delivered to the interior space of the vehicle floor member preform, the walls 106, 107 of the vehicle floor member preform deform, as best shown in fig. 33, which shows a longitudinal cross-section of a vehicle floor member manufactured from the vehicle floor member preform. As can be observed, the walls 106, 107 of the vehicle floor member preform are significantly deformed. Importantly, the vehicle floor member according to the present embodiment of the invention has different geometric dimensions in the front bumper portion 104, the front frame portion 101, the rear frame portion 102, and the rear bumper portion 105. The choice of these geometries depends on the requirements used with respect to the safety parameters (i.e. rigidity and strength of the structure, formation of controlled crumple zones) and the geometry of the load-bearing body structure. These geometries can be freely changed as desired and tailored to a particular application.

It should be noted that while the introduction of the pressurized fluid into the interior space of the vehicle floor member preform is performed under cold technology (i.e., room temperature), this is not a limitation on the scope of the invention, and in alternative embodiments this process may be performed at elevated or elevated temperatures.

process temperature: 20 c,

-working pressure: 2 bar of the total weight of the product,

pressure retention time: for a period of 30 seconds,

total deformation time: 1.5 minutes.

Example 7

Another embodiment of the present invention is shown in the top view of fig. 20, which shows a vehicle floor member preform.

In general, the vehicle floor member preform and the vehicle floor member manufactured therefrom are substantially similar to the structure of the vehicle floor member preform and the structure of the vehicle floor member shown in embodiment 6, and thus, for the sake of clarity of the present disclosure, description of similar structural elements will not be repeated.

Importantly, unlike example 6, the vehicle floor member preform (and corresponding vehicle floor member) shown in fig. 20 is made of a metal plate that does not have a uniform thickness over the entire surface area of the vehicle floor member preform, but has regions of different thickness that are connected to each other and form a "stitched" structure.

As shown in fig. 20, the side frame preform is composed of three regions of plates (stainless steel plates in this embodiment) having different thicknesses, which are schematically indicated by corresponding cross-sectional lines. In this embodiment, the region having a first thickness of 2mm is indicated by a horizontal line and includes the front bumper portion 104 and the rear bumper portion 105, the region having a second thickness of 1.5mm is indicated by a diagonal line and includes the side frame portion 103, and the region having a third thickness of 1.2mm is indicated by a vertical line and includes the front frame portion 101, the rear frame portion 102, and the frame longitudinal rib 114.

As a result, the inner wall 106 and the outer wall 107 are metal sheets having different thicknesses in respective portions of the vehicle floor member (and corresponding vehicle floor member preform). As a result of the use of the splice-type structure, the final vehicle floor member is imparted with desired functional characteristics, manifested by increased strength and rigidity in areas with increased plate thickness. Importantly, the structure of the inner wall 106 and the outer wall 107 is an integrated structure comprising regions of lesser and greater thickness of sheet metal. The inner wall 106 and/or the outer wall 107 of the areas of different thickness may be obtained by any method known in the art, including, in a non-limiting manner, selective press forming, rolling and joining of plates of different thickness, for example by welding.

Further, unlike embodiment 6, the vehicle floor member preform of this embodiment includes at least a frame longitudinal rib 114 that extends between the front frame portion 101 and the rear frame portion 102 and separates the storage opening. These frame longitudinal ribs 114 extend substantially parallel with respect to the corresponding side frame portions 103 and in this embodiment are material integration members with the rest of the vehicle floor member preform. It should be noted, however, that in alternative embodiments, these longitudinal ribs 114 may be separate structures from the remainder of the vehicle floor member preform that are mounted to the respective areas of the front and rear frame portions 101, 102 (e.g., as shown in fig. 21, 23, and 25) while being additional reinforcements to the structure of the final vehicle floor member. The type of connection between the frame longitudinal ribs 114 and the corresponding portions of the floor member preform is not limiting to the scope of the invention and may be any connection technique known in the art, such as pressure welding, bolting, crimping, gluing, etc. Importantly, the number of frame longitudinal ribs 114 used is also not limited to two, and in alternative embodiments fewer or more longitudinal ribs 114 may be used to achieve the desired technical characteristics of the vehicle floor member. For example, FIG. 26 shows a floor member preform including three frame longitudinal ribs 114.

Where the longitudinal rib 114 is a separate component from the remainder of the floor member preform, it may be a component that reproduces the structure of the other structural components of the floor member and is provided with a separate valve element 108 to introduce pressurized fluid into its interior space.

In another alternative embodiment of the present invention, as shown in fig. 26 and as shown in the corresponding cross section of fig. 35, unlike embodiment 6, the vehicle floor member preform (and corresponding vehicle floor member) is made of sheet metal having regions made of different materials, connected to each other, and forming a "material-stitched" structure.

As shown in fig. 26, the floor member preform is made of three regions made of different materials (stainless steel plate, carbon steel plate and black steel plate in this embodiment) schematically represented by corresponding line patterns. In this embodiment, the area made of the first material (material 1) is indicated by oblique lines and includes the front bumper portion 104, the rear bumper portion 105, and the side frame portions 103, the area made of the second material (material 2) is indicated by square lines and includes the frame center longitudinal rib 114, the front frame portion 101, and the rear frame portion 102, and the area made of the third material (material 3) is indicated by dots and includes the frame outer longitudinal rib 114.

As a result, the inner wall 106 and the outer wall 107 are metal sheets having different materials in respective portions of the vehicle floor member (and corresponding vehicle floor member preform). Due to the use of a material splice structure, the final vehicle floor member is given the desired functional properties, manifested by increased strength and stiffness in the areas where materials having such properties are present. Importantly, the structure of the inner wall 106 and the outer wall 107 is an integrated structure comprising regions made of different materials. The inner wall 106 and/or the outer wall 107 having regions made of different materials may be obtained by any method known in the art, including, in a non-limiting manner, joining plates made of different materials, for example by welding, pressure welding, soldering or gluing.

Example 8

Another embodiment of the invention is shown in fig. 21, which shows a top view of the floor element.

In general, the vehicle floor member preform and the vehicle floor member manufactured therefrom are substantially similar to the structure of the vehicle floor member preform and the structure of the vehicle floor member shown in embodiments 6 and 7, and thus, for the sake of clarity of the present disclosure, description of similar structural elements will not be repeated.

Unlike embodiments 6 and 7, in the embodiment shown in fig. 21, the floor member additionally includes reinforcing posts 116 in the areas of the front bumper portion 104 and the rear bumper portion 105. The first reinforcement column 116 extends from an outer portion of the front bumper portion 104 to the front frame portion 101, and the second reinforcement column 116 extends from an outer portion of the rear bumper portion 105 to the rear frame portion 102. The number and geometry and arrangement of the reinforcement posts 116 within the front and/or rear bumper portions 104, 105 is not a limitation on the scope of the present invention, and more or fewer reinforcement posts 116 arranged in different geometries may be used in alternative embodiments. A similar structure of reinforcement columns 116, which are members integral with the material of the other parts of the vehicle floor member preform, is shown in the embodiments illustrated in fig. 22, 23 and 28. It should be noted, however, that in alternative embodiments, the reinforcement posts 116 may be separate structures from the remainder of the vehicle floor member preform that are mounted to corresponding areas of the exterior portions of the front frame portion 101 and the front bumper portion 104 and/or the exterior portions of the rear frame portion 102 and the rear bumper portion 105 (e.g., as shown in fig. 24 and 25), as well as additional reinforcements for the structure of the final vehicle floor member. The type of connection between the reinforcing posts 116 and the corresponding portions of the floor member preform is not limiting to the scope of the invention and may be any connection technique known in the art, such as pressure welding, bolting, crimping, gluing, etc. Importantly, the number of reinforcement posts 116 used is also not limited to the number shown in the embodiments and illustrated in the drawings, and in alternative embodiments, fewer or more reinforcement posts 116 may be used to obtain the desired technical characteristics of the vehicle floor member.

Where the reinforcement column 116 is a separate component from the remainder of the floor member preform, it may be a component that reproduces the structure of the other structural components of the floor member and is provided with a separate valve element 108 to introduce pressurized fluid into its interior space.

Importantly, the floor member shown in fig. 21 has flattened areas 109 on the inner wall 106 and the outer wall 107, wherein the flattened areas 109 have a substantially flat outer surface. The flattened area 109 allows for additional adjustments to the technical parameters of the individual vehicle floor member sections and is also the mounting area for additional final equipment of the vehicle.

The planarized region 109 may be obtained by using a method for manufacturing a vehicle floor member according to another embodiment of the present invention. Unlike the method for manufacturing a vehicle floor member shown in embodiment 6, in the method for manufacturing a floor member of the present embodiment, before the step of introducing a pressurized fluid into the interior space of the vehicle floor member preform, the vehicle floor member preform is placed between the pressure plates 113 such that the pressure plates 113 are in contact with the walls 106, 107 of the vehicle floor member preform, as shown in fig. 4. The pressure plate 113 may be a working element of a mechanical press. In this case, a controlled force may be applied to the pressure plate 113, in particular in a direction towards the vehicle floor member preform. In the step of delivering the pressurized fluid into the sealed interior space of the vehicle floor member preform, the vehicle floor member preform is held between the pressure plates 113. As a result, the vehicle floor member portion manufactured in this way has flattened areas 109 in desired vehicle floor member areas where the lining of the pressure panel 113 is applied. The cross section of fig. 32A shows a vehicle floor member having a region deformed in a free manner (the pressure plate 113 is not used—the central member) and having a region (the outer member) having the flattened region 109 deformed by using the pressure plate 113. Further, the cross section of fig. 32B shows a vehicle floor member having a region deformed by using the pressure plate 113. This manufacturing method, which causes the structure shown in fig. 32A to be obtained, is implemented in the system shown in fig. 5 (only half of the vehicle floor member is shown for simplicity), in which one (left side) vehicle floor member portion is not in contact with the lining of the pressure plate 113 and can be deformed in a free manner, while the second (right side) vehicle floor member portion includes a wall in contact with the pressure plate 113. Thus, it is possible to provide a mounting area for the vehicle functional equipment for the desired location and to locally modify the technical properties of the vehicle floor member (such as the stiffness, strength of the structure) or to form a controlled crumple zone. In turn, fig. 33 shows a longitudinal section of a vehicle floor member having regions that deform in a free manner (without the use of pressure plates 113), the regions having different geometries (including different wall 106, 107 thicknesses) and also having different vehicle floor member region thicknesses after deformation. The longitudinal section of fig. 33 corresponds to a vehicle floor member formed from the vehicle floor member preform shown in fig. 19.

Example 9

Another embodiment of the present invention is shown in fig. 27, which shows a top view of a vehicle floor member without an outer wall 107 and shows the internal structure of the vehicle floor member.

In general, the vehicle floor member preform and the vehicle floor member manufactured therefrom are substantially similar to the structures of the vehicle floor member preform and the vehicle floor member shown in embodiments 6, 7 and 8, and thus, for the sake of clarity of the present disclosure, description of similar structural elements will not be repeated.

Unlike the previous embodiments, the floor member shown in the embodiment shown in fig. 27 additionally includes frame transverse ribs 115 extending between the frame longitudinal ribs 114 located adjacent the side frame portions 103. The frame transverse rib 115 extends substantially perpendicularly relative to the corresponding frame longitudinal rib 114 and in this embodiment is a component integral with the material of the remainder of the vehicle floor component preform.

It should be noted, however, that in alternative embodiments, the transverse rib 115 may be a separate structure from the remainder of the vehicle floor member preform (not shown) that is mounted to the longitudinal rib 114 or a corresponding region of the side frame portion 103, and at the same time is an additional reinforcement of the structure of the final vehicle floor member. The type of connection between the frame transverse ribs 115 and the corresponding portions of the floor member preform is not limiting to the scope of the invention and may be any connection technique known in the art, such as pressure welding, bolting, crimping, gluing, etc. Importantly, the number of frame transverse ribs 115 used is also not limited to one, and in alternative embodiments fewer or more transverse ribs 115 may be used to achieve the desired technical characteristics of the vehicle floor member. For example, fig. 28 shows a floor member comprising four frame transverse ribs 115, wherein these frame transverse ribs 115 extend between the side frame portions 103 and the frame longitudinal ribs 114 located nearby.

Where the transverse rib 115 is a separate component from the remainder of the floor member preform, it may be a component that reproduces the structure of the other structural components of the floor member and is provided with a separate valve element 108 to introduce pressurized fluid into its interior space.

As depicted in fig. 27, unlike the vehicle floor member preform and the corresponding vehicle floor member according to the previous embodiments, the vehicle floor member according to this embodiment includes an additional internal structure in the form of an internal pocket 110. An inner bag 110 is disposed in the gap between the inner wall 106 and the outer wall 107, as best shown in the cross-section of fig. 34. The interior bag 110 shown in fig. 27 is a leak-proof, airtight structure in fluid communication with a valve element 108 that passes through the inner wall 106 or the outer wall 107 of the vehicle floor member while the interior space of the vehicle side frame itself remains sealed. The inner bag 110 may be formed similarly to the floor member preform, i.e., formed of metal plates connected to each other and sealed on edges. In alternative embodiments, the inner bag 110 may be formed of other materials that provide an airtight seal to the container formed therein and include, in a non-limiting manner, a textile material.

The embodiment of the vehicle floor member shown in fig. 27 shows two interior pockets 110, wherein a first interior pocket 110 extends partially through the front bumper portion 104, the side frame portion 103, and partially through the rear bumper portion 105. The second interior pocket 110 is disposed on the opposite side of the vehicle floor member and is a specular reflection of the first interior pocket 110.

The inner bag 110 used in the vehicle floor member produces different results depending on its purpose. In this embodiment, the right inner bag 110 is made of carbon steel plate, wherein the entire structure of the vehicle floor member is made of stainless steel plate. Carbon steel has higher hardness and strength than stainless steel, and thus the inner bag 110 made of carbon steel is an element that increases the strength of the vehicle floor member to provide it with desired technical characteristics. In addition, after the vehicle floor member has been formed (by deforming the preform), the right inner bag 110 is deformed by the fluid (air) introduced into the airtight inner space thereof, thereby allowing additional local deformation to be generated in the vehicle floor member that has been formed and allowing the geometric shape of the vehicle floor member to be adjusted to a desired shape.

In the embodiment shown in fig. 27, the left inner bag 110 is made of a textile material (e.g., kevlar) forming a compartment in which the filler 111 is present (as shown in fig. 34). In this embodiment, the filler 111 is a non-newtonian fluid that allows for the formation of a substantially tuned damping region. The interior bag 110 with the non-newtonian fluid may be a separate structure that is introduced into the vehicle floor member preform. Alternatively, the interior bag 110 may be filled with the non-newtonian fluid after the vehicle floor member has been formed. In the latter case, the inner bag 110 requires a valve element 108 for introducing the filler 111.

Importantly, the type of filler 111 present in the inner bag 110 is not limited to non-newtonian fluids, and in alternative embodiments, the filler 111 may be such that desired technical characteristics (e.g., sound insulation levels) are ensured, and may include one-component, two-component, or three-component foams.

Example 10

Another embodiment of the present invention is shown in fig. 29, which shows an isometric view of a vehicle flooring system. In this embodiment, the vehicle flooring system includes two vehicle flooring members of the present invention as disclosed in the previous embodiments. These vehicle floor members are arranged one above the other with a proper gap maintained between them. In the embodiment shown in fig. 29, the lower vehicle floor member is the vehicle floor member shown in fig. 20, and the upper vehicle floor member is the vehicle floor member shown in fig. 21. It should be noted, however, that the vehicle flooring system is not limited to the structure shown in fig. 29, and in alternative embodiments it may be any combination of vehicle flooring members according to the present invention, particularly the combination of members presented in the foregoing embodiments, as well as combinations of more than two members.

One of the alternative embodiments of the vehicle flooring system is shown in fig. 30, wherein the lower vehicle flooring member is the vehicle flooring member shown in fig. 24, and the upper vehicle flooring member is the vehicle flooring member shown in fig. 19. Unlike the vehicle flooring system shown in fig. 29, the embodiment of fig. 30 additionally includes side panels 117 that connect with corresponding edges of each vehicle flooring member and ensure that the vehicle flooring members maintain a defined distance relative to each other. In the embodiment shown in fig. 30, there are six side plates 117, two of which are located on opposite sides of the corresponding front bumper portion 104, two are located on opposite sides of the corresponding side frame portion 103, and the remaining two are located on opposite sides of the corresponding rear bumper portion 105.

In the embodiment shown in fig. 30, the side plates 117 are members deformed by the pressurized fluid introduced into their inner spaces, i.e., they are manufactured by the technique of the other portions of the vehicle floor member according to the present invention. Fig. 31 shows the vehicle flooring system of fig. 30 with suspension components installed.

Example 11

The vehicle floor member manufactured using the method according to the present invention was subjected to a comparative test (based on numerical calculation) with the vehicle floor member manufactured using the conventional technique.

Fig. 36 to 39 show displacement maps of these vehicle floor members in two load states (displacement map in the Z-axis in the case of bending and rotation, and displacement map in the X-axis in the case of torsion). Analysis was made for the case of twisting and bending the vehicle floor member. The same boundary conditions are maintained for all numerical models. In the case of twisting, all floor members are fixed at the rear portion (at the center of the rear bumper portion 105), and the front portion is twisted by an angle equal to 1 °. In the case of bending, all frames are supported at two points (at the center of the front bumper portion 104 and the rear bumper portion 105), and a force corresponding to a mass of 100N is applied at the center portion (at the center of the side frame portions 103). In the stress profile, the legends for the load cases (twist/bend) are presented in the same scale. The rotation value (in degrees) under torsion corresponds to the loading at a torsion moment m=100 Nm. The material used in the simulation was steel with young's modulus e= 206.94GPa, poisson's ratio v=0.288, density ρ=7829 kg/m ³ 。

Fig. 36 and 37 are displacement diagrams for the floor member according to the present invention. Fig. 38 and 39 are displacement diagrams for a floor member manufactured in a conventional technology using a classical rectangular profile.

The calculated intensity parameters are presented in table 3.

TABLE 3 comparison of vehicle floor Member Strength parameters

As shown in table 3, the floor member according to the present invention was lighter than the floor member made of the standard profile (1.0 mm plate thickness for the 60x 20x 1.5mm rectangular profile and 1.2mm plate thickness for the 70x 20x 1.5mm rectangular profile), while showing similar torsional rigidity parameters and much higher bending rigidity parameters.

Example 12

Fig. 40 shows an isometric view of a vehicle integral body frame using two vehicle frame longitudinal members according to an embodiment of the invention. This embodiment is shown in the form of a vehicle frame longitudinal member preform in the side view of fig. 41 and in the form of a vehicle frame longitudinal member manufactured therefrom in the side view of fig. 42, the isometric view of fig. 43 and the cross-sectional view of fig. 44.

As shown in fig. 41, the vehicle frame longitudinal member preform is a longitudinal structure in its side view, which includes a front portion 201 configured to be arranged in a front portion of the vehicle body frame, a central portion 202 arranged in a central region of the vehicle body frame, and a rear portion 203 configured to be arranged in a rear portion of the vehicle body frame. Schematic views of the arrangement of the vehicle frame longitudinal member with respect to the vehicle body frame according to this embodiment are shown in fig. 42 and 43. The vehicle frame longitudinal member preform shown in fig. 41 includes a central portion 202 that moves toward the bottom of the vehicle body frame relative to a front portion 201. In this embodiment, the rear portion 203 is substantially aligned with the front portion 201. Between the front portion 201 and the central portion 202, a transition region may be defined, which has a portion of the vehicle frame longitudinal member preform that is inclined in the bottom direction. Similarly, between the rear portion 203 and the central portion 202, a transition region may be defined having a portion of the vehicle frame longitudinal member preform that is inclined toward the bottom. There are also two bottom protrusions near the ends of the central portion 202, these two bottom protrusions 214 being recesses in the longitudinal direction of the vehicle frame longitudinal member preform. These bottom protrusions 214 are the lowermost regions protruding to the vehicle frame longitudinal member preform and they serve as connecting members for connecting floor members that are part of the vehicle floor member system.

The above-described components of the vehicle frame longitudinal member preform are connected to each other and form an integral part made of a metal plate (such as a steel plate having a thickness of 2 mm) defining an inner wall 206 and an outer wall 207 (see, for example, fig. 44, which is a cross section of a vehicle frame longitudinal member manufactured from the vehicle frame longitudinal member preform of fig. 41). The thickness of the metal plate is not limited to the values provided above, and in alternative embodiments, metal plates having a thickness in the range of 1mm to 5mm may be used depending on the structural and strength requirements of the final vehicle frame longitudinal member.

It should be emphasized that the sheet thickness of the vehicle frame longitudinal member preform is not limiting to the scope of the invention, and that in alternative embodiments of the invention, metal sheets having different thicknesses and made of different materials may be used. The concepts of the inner wall 206 and the outer wall 207 are conventional and are intended to represent the inside and outside, respectively, of a vehicle in which the vehicle frame longitudinal member of the present invention is used. The inner wall 206 and the outer wall 207 are arranged in alignment (in plan) with respect to each other while providing a gap that forms a closed, empty interior space of the vehicle frame longitudinal member preform. A valve element 208 is arranged on one of the walls 206, 207, which valve element allows fluid communication with the interior space formed between the walls 206, 207 of the vehicle frame longitudinal member preform.

The valve element 208 is a pneumatic or hydraulic connection and allows for leak-proof fastening of a supply conduit from an external pressurized fluid source. In some embodiments of the present invention, valve element 208 may be a valve, particularly a check valve. The location of the valve element 208 is not limiting to the scope of the invention, and thus the valve element 208 may be disposed in any location on the sheet metal provided that connection with the interior space of the vehicle frame longitudinal member preform is permitted.

In this embodiment, the outer edges of the vehicle frame longitudinal member preform are sealed with a seal 212, thereby forming a closed, airtight, empty interior space of the vehicle frame longitudinal member preform.

After the walls 206, 207 of the vehicle frame longitudinal member preform have been mated with each other, sealing is performed on the edges of the metal sheets forming these walls. In this embodiment, sealing is thus performed on all circumferential edges of the mating walls 206, 207 of the vehicle frame longitudinal member preform. In this embodiment, the sealing is performed by welding the corresponding edges together, in particular to form a circumferential weld. By sealing all of the above edges, a leak-proof, airtight interior space is formed in the vehicle frame longitudinal member preform. In this case, the type of seal 212 is not a limitation on the scope of the invention, and any type of seal 212 may be used in alternative embodiments, so long as a leak-proof interior space is formed in the vehicle frame longitudinal member preform, for example, by pressure welding, soldering, gluing, bending, or pressing.

A method for manufacturing a vehicle frame longitudinal member according to one of the embodiments of the invention comprises the step of providing a vehicle frame longitudinal member preform as defined in the present embodiment. In the event that the provided vehicle frame longitudinal member preform does not have all of its circumferential edges connected and sealed, the next step includes sealing the unconnected edges of the vehicle frame longitudinal member preform with a seal 212 to form a closed, airtight, empty interior space of the vehicle frame longitudinal member preform. As described above, the seal 212 may be implemented in any known manner that ensures that a leak-proof interior space is formed.

In a next step, an external pressurized fluid source is connected to valve element 208 through a supply conduit. In this embodiment, the fluid is air, the pressurized fluid source is a compressor, and the supply conduit forms a pneumatic connection with the valve element 208. The type of external pressurized fluid source and connection equipment is not limiting to the scope of the invention and in alternative embodiments, fluids may be used with connection equipment and pressurized fluid sources suitable for such fluids in the form of water, fluid cement, engine oil, fluid plastics such as one-component, two-component or three-component foams (e.g., flex140 type), flowable natural materials such as liquid rubber, and the like. The less compressible the fluid, the more controlled the deformation conditions of the vehicle frame longitudinal member preform.

In a further step of the method for manufacturing a vehicle frame longitudinal member according to the invention, a fluid under defined pressure is delivered to the sealed interior space of the vehicle frame longitudinal member preform. From patent application No. EP 2110189A1, a technique is known in particular for introducing a pressurized fluid into closed, sealed chamber elements made of sheet metal in order to deform them and to provide them with a final form. As a result of the pressurized fluid being delivered to the interior space of the vehicle frame longitudinal member preform, the walls 206, 207 of the vehicle frame longitudinal member preform deform, as best shown in fig. 44, which shows a cross section of a vehicle frame longitudinal member manufactured from the vehicle frame longitudinal member preform. As can be observed, the walls 206, 207 of the vehicle frame longitudinal member preform are significantly deformed.

Importantly, the vehicle frame longitudinal member according to the present embodiment of the invention has different geometric dimensions in the front portion 201, the central portion 202 and the rear portion 203. The choice of these geometries depends on the requirements used with respect to the safety parameters (i.e. rigidity and strength of the structure, formation of controlled crumple zones) and the geometry of the load-bearing body structure. These geometries can be freely changed as desired and tailored to a particular application.

It should be noted that while the introduction of the pressurized fluid into the interior space of the vehicle frame longitudinal member preform is performed under cold technology (i.e., room temperature), this is not a limitation on the scope of the invention, and in alternative embodiments this process may be performed at elevated or elevated temperatures.

process temperature: 20 c,

-working pressure: 2 bar of the total weight of the product,

pressure retention time: for a period of 30 seconds,

total deformation time: 1.5 minutes.

Example 13

Another embodiment is shown in the form of a vehicle frame longitudinal member preform in the side view of fig. 45 and in the form of a vehicle frame longitudinal member made therefrom in the side view of fig. 46, in the isometric view of fig. 47, and in the cross-sectional view of fig. 48.

In general, the vehicle frame longitudinal member preform and the vehicle frame longitudinal member manufactured therefrom are substantially similar structures to those of the vehicle frame longitudinal member preform and the vehicle frame longitudinal member shown in embodiment 12, and thus, for the sake of clarity of the present disclosure, description of similar structural elements will not be repeated.

Importantly, unlike example 12, the vehicle frame longitudinal member preform (and corresponding vehicle frame longitudinal member) shown in fig. 45 is made of sheet metal that does not have a uniform thickness over the entire surface area of the vehicle frame longitudinal member preform, but rather has regions of differing thickness that are connected to each other and form a "stitched" structure.

As shown in fig. 45, the vehicle frame longitudinal member preform is constituted by three regions of a material plate (stainless steel plate in this embodiment) having different thicknesses, which are schematically indicated by respective cross-sectional lines. In this embodiment, the area having a first thickness of 2mm is indicated by oblique lines and comprises the front portion 201 and the transition between the front portion 201 and the central portion 202, the area having a second thickness of 1.5mm is indicated by dots and comprises the front section of the central portion 202, and the area having a third thickness of 1.2mm is indicated by vertical lines and comprises the rear section of the central portion 2.

As a result, the inner wall 206 and the outer wall 207 are metal plates having different thicknesses in respective portions of the vehicle frame longitudinal member (and corresponding vehicle frame longitudinal member preform). Due to the use of the spliced structure, the final vehicle frame longitudinal member is given the desired functional properties, manifested by increased strength and rigidity in the region with increased plate thickness. Importantly, the structure of the inner wall 206 and the outer wall 207 is an integrated structure comprising regions of lesser and greater thickness of sheet metal. The inner wall 206 and/or the outer wall 207 of the areas of different thickness may be obtained by any method known in the art, including, in a non-limiting manner, selective press forming, rolling and joining of plates of different thickness, for example by welding.

Further, unlike embodiment 12, the vehicle frame longitudinal member preform of this embodiment has no rear portion, and thus includes only the front portion 201 and the center portion 202. As best shown in the side view of fig. 46, the frame longitudinal member manufactured from such a preform is intended to be mounted in the front portion and the center portion of the vehicle body frame.

Furthermore, the vehicle frame longitudinal member preform of this embodiment and the vehicle frame longitudinal member manufactured therefrom have in its front portion 201 an annular structure 204 which provides a connecting surface for connecting the floor member and which structure has increased strength and stability in this area, in particular in order to withstand deformation caused by an impact from the front. In addition, by providing the annular structure 204 instead of a full structure (without openings), the mass of the final vehicle frame longitudinal member can be reduced.

Further, unlike embodiment 12, the vehicle frame longitudinal member preform of this embodiment, and the vehicle frame longitudinal member made therefrom, includes a transition annular structure 205 in the transition region between the front portion 201 and the central portion 202, as best shown in fig. 45. The purpose of the transition ring structure 205 is to provide a connection surface for connecting floor elements, as well as increased strength and stability and reduced mass of the structure.

Example 14

Another embodiment is shown in the form of a vehicle frame longitudinal member preform in the side view of fig. 49 and in the form of a vehicle frame longitudinal member made therefrom in the side view of fig. 50, in the isometric view of fig. 51 and in the cross-sectional view of fig. 52.

Unlike embodiment 12, in the embodiment shown in fig. 49, the vehicle frame longitudinal member preform additionally includes a central annular structure 209 located in the region of the central portion 202. Furthermore, two stiffening ribs 210 are located in the central portion 202, which extend through the opening defined by the central annular structure 209 and connect opposite longitudinal regions of the central annular structure 209.

The number and geometry and arrangement of the stiffening ribs 210 within the central annular structure 209 are not limiting to the scope of the invention and in alternative embodiments, more or fewer stiffening ribs 210 arranged in different geometries may be used. However, it should also be noted that in alternative embodiments, the stiffening ribs 210 may be separate structures with respect to the remainder of the vehicle frame longitudinal member preform, which are mounted to corresponding areas of the central annular structure 209, and at the same time are additional stiffeners of the structure of the final vehicle frame longitudinal member. The type of connection between the reinforcing ribs 210 and the corresponding portions of the vehicle frame longitudinal member preform is not limiting to the scope of the invention and may be any connection technique known in the art, such as pressure welding, bolting, crimping, gluing, etc. Importantly, the number of ribs 210 used is not limited to the number shown in the embodiments and illustrated in the drawings, and in alternative embodiments fewer or more ribs 210 may be used to achieve the desired technical characteristics of the vehicle frame longitudinal member.

In the case where the reinforcement rib 210 is a separate member from the other portion of the vehicle frame longitudinal member preform, it may be a member that reproduces the structure of the other structural member of the vehicle frame longitudinal member and is provided with a separate valve element 208 to introduce the pressurized fluid into the inner space thereof.

In another alternative embodiment of the present invention, as shown in the corresponding cross-sections of fig. 50 and 51 and 52, unlike embodiment 12, the vehicle frame longitudinal member preform (and corresponding vehicle frame longitudinal member) is made of sheet metal having regions made of different materials, connected to each other, and forming a "material-stitched" structure.

As shown in fig. 49, the vehicle frame longitudinal member preform is made of three regions made of different materials (stainless steel plate, carbon steel plate, and black steel plate in this embodiment), schematically represented by corresponding line patterns. In this embodiment, the area made of the first material (material 1) is represented by diagonal lines and includes the front portion 2-1, the area made of the second material (material 2) is represented by dots and includes the center portion 202, and the area made of the third material (material 3) is represented by horizontal lines and includes the rear portion 203.

As a result, the inner wall 206 and the outer wall 207 are metal plates having different materials in respective portions of the vehicle frame longitudinal member (and corresponding vehicle frame longitudinal member preform). Due to the use of a material splice structure, the final vehicle frame longitudinal member is given the desired functional properties, manifested by increased strength and stiffness in the areas where material having such properties is present. Importantly, the structure of the inner wall 206 and the outer wall 207 is an integrated structure comprising regions made of different materials. The inner wall 206 and/or the outer wall 207 having regions made of different materials may be obtained by any method known in the art, including, in a non-limiting manner, joining plates made of different materials, for example by welding, pressure welding, soldering or gluing.

Example 15

Another embodiment is shown in the form of a vehicle frame longitudinal member preform in the side view of fig. 53 and in the form of a vehicle frame longitudinal member made therefrom in the side views of fig. 54 and 55, in the isometric view of fig. 56, and in the cross-sectional view of fig. 57.

Unlike embodiment 12, in the embodiment shown in fig. 53, the vehicle frame longitudinal member preform includes two end annular structures 204 in the front portion 201 and the rear portion 203, respectively. The purpose of the end ring structure 204 is to provide a connection surface for connecting the floor members, as well as increased strength and stability and reduced mass of the structure.

Importantly, the frame longitudinal member shown in fig. 54-57 has flattened regions 211 on the inner wall 206 and the outer wall 207, wherein the flattened regions 211 have a substantially flat outer surface. The flattened area 211 allows additional adjustments to be made to the technical parameters of the individual vehicle frame longitudinal member portions and is also a mounting area for additional final equipment of the vehicle. In particular, the width dimension of the vehicle frame longitudinal member can be controlled (especially reduced) to meet specific structural needs.

The flattened region 211 may be obtained by a method for manufacturing a vehicle frame longitudinal member according to another embodiment of the present invention. Unlike the method for manufacturing a vehicle frame longitudinal member shown in embodiment 12, in the method for manufacturing a vehicle frame longitudinal member of the present embodiment, before the step of introducing a pressurized fluid into the interior space of the vehicle frame longitudinal member preform, the vehicle frame longitudinal member preform is placed between the pressure plates 213 such that the pressure plates 213 are in contact with the walls 206, 207 of the vehicle frame longitudinal member preform, as shown in fig. 4. The pressure plate 213 may be a working element of a mechanical press. In this case, a controlled force may be applied to the pressure plate 213, in particular in a direction towards the vehicle frame longitudinal member preform. The vehicle frame longitudinal member preform is held between the pressure plates 213 during the step of delivering pressurized fluid into the sealed interior space of the vehicle frame longitudinal member preform. As a result, the vehicle frame longitudinal member portions manufactured in this way have flattened areas 211 in the desired vehicle frame longitudinal member areas where the inner lining of the pressure plate 213 is applied. The cross section of fig. 57 shows a vehicle frame longitudinal member having a region with a flattened region 211 deformed by using a pressure plate 213. This manufacturing method, which causes the structure shown in fig. 57 to be obtained, is implemented in the system shown in fig. 5, in which one vehicle frame longitudinal member portion is not in contact with the inner lining of the pressure plate 213 and can be deformed in a free manner, while the second vehicle frame longitudinal member portion includes a wall in contact with the pressure plate 213. Thus, it is possible to provide a mounting area for the vehicle functional equipment for the desired location and to locally modify the technical characteristics of the vehicle frame longitudinal member (such as the stiffness, strength of the structure) or to form a controlled crumple zone.

Example 16

The vehicle frame longitudinal member manufactured using the method according to the present invention was subjected to a comparative test (based on numerical calculation) with the vehicle frame longitudinal member manufactured using the conventional technique. For the purpose of performing comparative tests, a frame structure comprising frame longitudinal members of the schiff base 1500 (year of production 2014) was chosen. Fig. 58 shows a model of a vehicle frame based on a longitudinal member of a frame of the bergamot 1500 made from components according to the conventional technique, while fig. 59 shows a similar model of a vehicle frame based on a longitudinal member of a frame according to the invention made by the method of the invention. Further, fig. 60 shows a stress profile of the structure, which is the result of the torsion test of the modeled frame in fig. 59.

The same boundary conditions are maintained for all numerical models. The rotation value applied under torsion corresponds to the loading at a torsion moment m=100 Nm. The material used in the simulation was steel with young's modulus e= 206.94GPa, poiseThe apparent ratio=ν=0.288, the density ρ=7829 kg/m ³ . The individual constituent members of the frame based on the frame longitudinal members of the invention are made of sheet metal material with a thickness of 0.8mm to 2 mm.

The calculated intensity parameters are presented in table 4.

TABLE 4 comparison of the strength parameters of vehicle frames made from vehicle frame longitudinal members

As shown in table 4, the frames based on the frame longitudinal members of the present invention are lighter than the frames based on the frame longitudinal members made of standard profiles, while exhibiting more advantageous torsional stiffness parameters. In the case of the conventional technique, the frame is composed of 62 constituent members, whereas in the case of the technique of the present invention, the frame is composed of 74 constituent members, of which 58 are members manufactured with the technique of introducing pressurized fluid into closed sealed chamber elements made of sheet metal to deform them and provide them with the final form.

The LWI (light weight coefficient) parameters shown in table 4 are parameters used in the art for comparison purposes and define the structural efficiency of the structure. A lower value thereof indicates that a more advantageous structural efficiency is obtained. LWI parameters are defined in particular in Singh, harry (8 nd 2012.) weight loss of light vehicles of model year 2017-2025 (report number DOT HS 811666).

Example 17

Fig. 61 is an isometric view of a body frame as an embodiment of the invention. The illustrated vehicle body frame is manufactured by connecting two vehicle side frames as illustrated in the foregoing embodiment of fig. 2, two floor members as illustrated in the foregoing embodiment of fig. 19 and 20, and two vehicle frame longitudinal members as illustrated in the foregoing embodiment of fig. 42. In alternative embodiments, the body frame may be manufactured from fewer or more body frame constituent members, including any of the members shown in the foregoing embodiments of the vehicle side frames, vehicle floor members, and vehicle frame longitudinal members.

List of reference numerals:

1-front pillar portion

2-roof frame part

3-rear pillar portion

4-threshold portion

5-Central column section

6-inner wall

7-outer wall

8-valve element

9-planarization region

10-inner bag

11-Filler

12-seal

13-pressure plate

101-front frame portion

102-rear frame portion

103-side frame portion

104-front bumper portion

105-rear bumper portion

106-inner wall

107-outer wall

108-valve element

109-planarization region

110-inner bag

111-Filler

112-seal

113-pressure plate

114-frame longitudinal ribs

115-frame transverse rib

116-reinforcing column

117-side plate

201-front portion

202-central portion

203-rear portion

204-end ring structure

205-transition ring structure

206-inner wall

207-outer wall

208-valve element

209-central annular structure

210-reinforcing rib

211-planarization region

212-seal

213 pressure plate

Claims

1. A vehicle side frame preform having a substantially ring-shaped structure in a side view thereof, which substantially ring-shaped structure defines an access opening of the vehicle, the vehicle side frame preform comprising a front pillar portion (1), a roof frame portion (2), a rear pillar portion (3) and a threshold portion (4), characterized in that the vehicle side frame preform comprises an inner wall (6) and an outer wall (7) which are made of sheet metal, arranged in relation to each other while providing a gap, which gap forms a closed, empty interior space of the vehicle side frame preform, wherein a valve element (8) is arranged on at least one of the walls (6, 7).

2. The vehicle side frame preform according to claim 1, characterized in that the vehicle side frame preform further comprises at least one central pillar portion (5) extending between the roof frame portion (2) and the threshold portion (4) and separating an access opening of the vehicle.

3. Vehicle-side frame preform according to claim 1 or 2, characterized in that the vehicle-side frame preform has inner wall (6) areas and/or outer wall (7) areas with an increased thickness of the metal sheet.

4. A vehicle side frame preform according to any one of claims 1-3, characterized in that the vehicle side frame preform has at least one inner pocket (10) arranged in the gap between the inner wall (6) and the outer wall (7).

5. The vehicle side frame preform according to claim 4, characterized in that the inner bag (10) is in fluid communication with the valve element (8).

6. A vehicle side frame preform according to claim 4 or 5, characterized in that a filler (11) is present in the inner bag (10).

7. The vehicle side frame preform according to claim 6, characterized in that the filler (11) is a one-component, two-component or three-component foam or a non-newtonian fluid.

8. Vehicle side frame preform according to any of claims 1-7, characterized in that the outer edge and/or the inner edge of the vehicle side frame preform is sealed with a seal (12) so as to form a closed, airtight, empty interior space of the vehicle side frame preform.

9. The vehicle side frame preform of claim 8, wherein the seal (12) is a fusion weld, a press weld, an adhesive layer, or a lap joint.

10. The vehicle side frame preform according to any one of claims 1 to 9, characterized in that the valve element (8) is a pneumatic or hydraulic connection.

11. A method for manufacturing a vehicle side frame, characterized in that the method comprises the steps of:

a) Providing a vehicle side frame preform as defined in any one of claims 1 to 10,

b) Sealing the unattached edges of the vehicle side frame preform with the seal (12) to form a closed, airtight, empty interior space of the vehicle side frame preform,

c) A pressurized fluid is introduced through the valve element (8) into the interior space of the vehicle side frame preform to form a deformed vehicle side frame.

12. The method for manufacturing a vehicle side frame according to claim 11, characterized in that the method comprises the additional step of: pressurized fluid is introduced into the inner bag (10) through the valve element (8).

13. Method for manufacturing a vehicle side frame according to any of claims 11 or 12, characterized in that step c) is performed after introducing at least a part of the vehicle side frame preform between pressure plates (13) such that the pressure plates (13) are in contact with the walls (6, 7) of the vehicle side frame preform to introduce at least one flattened area (9) on a part of the vehicle side frame preform.

14. Method for manufacturing a vehicle side frame according to claim 13, characterized in that during step c) forces are applied to the pressure plates (13) in the direction of the vehicle side frame preform.

15. Method for manufacturing a vehicle side frame according to any of claims 11 to 14, characterized in that step c) is performed by connecting a pressurized fluid source to the valve element (8).

16. The method for manufacturing a vehicle side frame according to any one of claims 11 to 15, wherein step b) is achieved by fusion welding, pressure welding, gluing or crimping.

17. The method for manufacturing a vehicle side frame according to any one of claims 11 to 16, wherein the fluid is air, water, oil, fluid concrete or fluid plastic.

18. The method for manufacturing a vehicle side frame according to any one of claims 11 to 17, wherein step c) is performed at room temperature or an elevated temperature.

19. The method for manufacturing a vehicle side frame according to any one of claims 11 to 18, characterized in that the pressure of the fluid introduced into the vehicle side frame preform is at least 5 bar.

20. A vehicle side frame having a substantially ring-shaped structure defining an access opening for the vehicle in a side view thereof, the vehicle side frame comprising a front pillar portion (1), a roof frame portion (2), a rear pillar portion (3) and a threshold portion (4), characterized in that the vehicle side frame is deformed by a pressurized fluid introduced into its airtight, empty space formed by an inner wall (6) and an outer wall (7) connected to each other by a corresponding seal (12), wherein a valve element (8) is arranged on at least one of the walls (6, 7).

21. The vehicle side frame according to claim 20, characterized in that the vehicle side frame further comprises at least one central pillar portion (5) extending between the roof frame portion (2) and the door sill portion (4) and separating the access opening of the vehicle, wherein the central pillar portion (5) is deformed by the pressurized fluid.

22. Vehicle side frame according to claim 20 or 21, characterized in that the vehicle side frame has inner wall (6) areas and/or outer wall (7) areas with an increased thickness of the metal plate.

23. Vehicle side frame according to any of claims 20-22, characterized in that it has at least one inner pocket (10) arranged in the space between the inner wall (6) and the outer wall (7).

24. Vehicle side frame according to claim 23, characterized in that the inner bag (10) is in fluid communication with the valve element (8) and that pressurized fluid introduced into the interior of the inner bag (10) deforms the inner bag.

25. Vehicle side frame according to claim 23 or 24, characterized in that a filler (11) is present in the inner bag (10).

26. Vehicle side frame according to claim 25, characterized in that the filler (11) is a one-component, two-component or three-component foam or a non-newtonian fluid.

27. The vehicle side frame according to any one of claims 20 to 26, characterized in that the seal (12) is a fusion weld, a press weld, an adhesive layer, or a lap joint.

28. Vehicle side frame according to any of claims 20-27, characterized in that the valve element (8) is a pneumatic or hydraulic connection.

29. The vehicle side frame according to any one of claims 20 to 28, wherein the fluid is air, water, oil, fluid concrete or fluid plastic.

30. Vehicle side frame according to any of claims 20 to 29, characterized in that it has at least one flattened area (9) on the inner wall (6) and/or the outer wall (7).

31. A vehicle floor member preform having a substantially annular structure in a top view thereof, the substantially annular structure defining a storage opening, the vehicle floor member preform comprising a front frame portion (101), a rear frame portion (102), a plurality of side frame portions (103), a front bumper portion (104) extending from the front frame portion (101) and a rear bumper portion (105) extending from the rear frame portion (102), characterized in that the vehicle floor member preform comprises an inner wall (106) and an outer wall (107) made of sheet metal, arranged with respect to each other while providing a gap, the gap forming a closed, empty interior space of the vehicle floor member preform, wherein a valve element (108) is arranged on at least one of the walls (106, 107).

32. The vehicle floor member preform of claim 31, further comprising at least one frame longitudinal rib (114) extending between the front frame portion (101) and the rear frame portion (102) and separating the storage opening.

33. The vehicle floor member preform of claim 31 or 32, further comprising at least one frame transverse rib (115) extending substantially perpendicular to the side frame portion (103).

34. The vehicle floor member preform of claim 33, wherein the frame longitudinal rib (114) and/or the frame transverse rib (115) are separate members with respect to the substantially annular structure of the vehicle floor member.

35. The vehicle floor member preform according to any one of claims 31-34, further comprising at least one reinforcement pillar (116) in the area of the front bumper portion (104) and/or the area of the rear bumper portion (105).

36. The vehicle floor member preform of claim 35, wherein the reinforcement column (116) is a separate member with respect to the front bumper portion (104) and/or the rear bumper portion (105).

37. The vehicle floor member preform according to any one of claims 31-36, wherein the vehicle floor member preform has an inner wall (106) region and/or an outer wall (107) region, the regions having an increased thickness of the metal sheet.

38. The vehicle floor member preform of any one of claims 31 to 37, wherein the vehicle floor member preform has an inner wall (106) region and/or an outer wall (107) region made of different materials.

39. The vehicle floor member preform according to any one of claims 31-38, wherein the vehicle floor member preform has at least one inner pocket (110) arranged in a gap between the inner wall (106) and the outer wall (107).

40. The vehicle floor member preform of claim 39, wherein the inner bag (110) is in fluid communication with the valve element (108).

41. The vehicle floor member preform according to claim 39 or 40, wherein a filler (111) is present in the inner bag (110).

42. The vehicle floor member preform of claim 41, wherein the filler (111) is a one, two or three-component foam or a non-newtonian fluid.

43. A vehicle floor member preform according to any one of claims 31-42, wherein the outer and/or inner edges of the vehicle floor member preform are sealed with a seal (112) thereby forming a closed, air tight, empty interior space of the vehicle floor member preform.

44. The vehicle floor member preform of claim 43, wherein the seal (112) is a fusion weld, a press weld, an adhesive layer, or a lap joint.

45. The vehicle floor member preform according to any one of claims 31 to 44, wherein the valve element (108) is a pneumatic or hydraulic connection.

46. A method for manufacturing a vehicle floor member, characterized by comprising the steps of:

a) Providing a vehicle floor member preform according to any one of claims 31 to 45,

b) Sealing the unattached edge of the vehicle floor member preform with the seal (112) to form a closed, airtight, empty interior space of the vehicle floor member preform,

c) Pressurized fluid is introduced through the valve element (108) into the interior space of the vehicle floor member preform to form a deformed vehicle floor member.

47. The method for manufacturing a vehicle floor member according to claim 46, wherein the method comprises the additional step of: pressurized fluid is introduced into the inner bag (110) through the valve element (108).

48. Method for manufacturing a vehicle floor member according to any one of the claims 46 or 47, wherein step c) is performed after introducing at least a part of the vehicle floor member preform between pressure plates (113) such that the pressure plates (113) are in contact with the walls (106, 107) of the vehicle floor member preform to introduce at least one flattened area (109) on a part of the vehicle floor member preform.

49. The method for manufacturing a vehicle floor member according to claim 48, wherein during step c), forces are applied to the pressure plates (113) in the direction of the vehicle floor member preform.

50. Method for manufacturing a vehicle floor member according to any one of the claims 46 to 49, wherein step c) is performed by connecting a pressurized fluid source to the valve element (108).

51. The method for manufacturing a vehicle floor member according to any one of claims 46 to 50, wherein step b) is achieved by fusion welding, pressure welding, gluing or crimping.

52. The method for manufacturing a vehicle floor member according to any one of claims 46 to 51, wherein the fluid is air, water, oil, fluid concrete, fluid plastic or flowable natural material.

53. The method for manufacturing a vehicle floor member according to any one of claims 46 to 52, wherein step c) is performed at room temperature or an elevated temperature.

54. The method for manufacturing a vehicle floor member according to any one of claims 46 to 53, wherein the pressure of the fluid introduced into the vehicle floor member preform member is at least 2 bar.

55. A vehicle floor member having a substantially annular structure defining a storage opening in a top view thereof, the vehicle floor member comprising a front frame portion (101), a rear frame portion (102), a plurality of side frame portions (103), a front bumper portion (104) extending from the front frame portion (101) and a rear bumper portion (105) extending from the rear frame portion (102), characterized in that the vehicle floor member is deformed by a pressurized fluid introduced into an airtight, empty space thereof, the space being formed by an inner wall (106) and an outer wall (107) connected to each other by a corresponding seal (112), wherein a valve element (108) is arranged on at least one of the walls (106, 107).

56. The vehicle floor member of claim 55, further comprising at least one frame longitudinal rib (114) extending between the front frame portion (101) and the rear frame portion (102) and separating the storage opening, wherein preferably the frame longitudinal rib (114) is deformed by the pressurized fluid.

57. Vehicle floor element according to claim 55 or 56, characterized in that the vehicle floor element further comprises at least one frame transverse rib (115) extending substantially perpendicular to the side frame part (103), wherein preferably the pressurized fluid deforms the frame transverse rib (115).

58. The vehicle floor member as claimed in claim 57, wherein the frame longitudinal rib (114) and/or the frame transverse rib (115) are separate members from and connected to the substantially annular structure of the vehicle floor member.

59. The vehicle floor member according to any one of claims 55 to 58, further comprising at least one reinforcement post (116) in the area of the front bumper portion (104) and/or in the area of the rear bumper portion (105), wherein preferably the reinforcement post (116) is deformed by the pressurized fluid.

60. The vehicle floor member as claimed in claim 59, wherein the reinforcement post (116) is a separate member with respect to and connected to the front bumper portion (104) and/or the rear bumper portion (105).

61. The vehicle floor member as claimed in any one of claims 55-60, wherein the vehicle floor member has an inner wall (106) area and/or an outer wall (107) area, the areas having an increased thickness of the metal plate.

62. The vehicle floor member as claimed in any one of claims 55-61, wherein the vehicle floor member has an inner wall (106) area and/or an outer wall (107) area made of different materials.

63. The vehicle floor member according to any one of claims 55-62, characterized in that the vehicle floor member has at least one inner pocket (110) arranged in the space between the inner wall (106) and the outer wall (107).

64. The vehicle floor member of claim 63, wherein the inner bag (110) is in fluid communication with the valve element (108) and pressurized fluid introduced into the interior of the inner bag (110) deforms the inner bag.

65. The vehicle floor member according to claim 63 or 64, wherein a filler (111) is present in the inner bag (110).

66. The vehicle floor member as claimed in claim 65, wherein the filler (111) is a one, two or three-component foam or non-newtonian fluid.

67. The vehicle floor member of any one of claims 55 to 66, wherein the seal member (112) is a fusion welded member, a press welded member, an adhesive layer, or a lap joint.

68. The vehicle floor member according to any one of claims 55-67, wherein the valve element (108) is a pneumatic or hydraulic connection.

69. The vehicle floor member of any one of claims 55 through 68, wherein the fluid is air, water, oil, fluid concrete, fluid plastic or flowable natural material.

70. The vehicle floor member as claimed in any one of claims 55-69, wherein the vehicle floor member has at least one flattened area (109) on the inner wall (106) and/or the outer wall (107).

71. A vehicle flooring system comprising at least two vehicle flooring members as claimed in any one of claims 55 to 70, wherein the at least two vehicle flooring members are arranged one above the other.

72. The vehicle flooring system of claim 71, having at least one side panel (117) connected to a corresponding edge of each vehicle flooring member and ensuring that the vehicle flooring members maintain a defined distance relative to each other.

73. The vehicle flooring system of claim 72, wherein the side panels (117) are located in the region of the side frame portions (103), the front bumper portion (104) and/or the rear bumper portion (105).

74. The vehicle flooring system of claim 72 or 73, wherein the side panel (117) is a member deformed by a pressurized fluid introduced into the interior of the side panel.

75. A vehicle frame longitudinal member preform having a longitudinal structure in a side view thereof, the longitudinal structure comprising a front portion (201) oriented towards the front of the vehicle frame and a central portion (202) arranged in the central portion of the vehicle frame, characterized in that the vehicle frame longitudinal member preform comprises an inner wall (206) and an outer wall (207) made of sheet metal, arranged relative to each other while providing a gap forming a closed, empty interior space of the vehicle frame longitudinal member preform, wherein a valve element (208) is arranged on at least one of the walls (206, 207).

76. The vehicle frame longitudinal member preform of claim 75, further comprising a rear portion (203) oriented toward a rear of the vehicle frame.

77. The vehicle frame longitudinal member preform of claim 75 or 76, wherein the central portion (202) is offset relative to the front portion (201) toward the bottom of the vehicle frame.

78. The vehicle frame longitudinal member preform of any of claims 75-77, wherein the front portion (201) and/or the rear portion (203) comprises an end ring structure (204).

79. The vehicle frame longitudinal member preform of any of claims 75-78, wherein a transition region between the front portion (201) and the central portion (202) comprises a transition annular structure (205).

80. The vehicle frame longitudinal member preform of any of claims 75-79, wherein the central portion (202) comprises a central annular structure (209).

81. The vehicle frame longitudinal member preform of claim 80, wherein the central portion (202) comprises at least one stiffening rib (210) extending through an opening defined by the central annular structure (209).

82. The vehicle frame longitudinal member preform of any one of claims 75-81, wherein the vehicle frame longitudinal member preform has inner wall (206) regions and/or outer wall (207) regions having an increased thickness of the metal sheet.

83. The vehicle frame longitudinal member preform of any of claims 75-82, wherein the vehicle frame longitudinal member preform has an inner wall (206) region and/or an outer wall (207) region made of different materials.

84. The vehicle frame longitudinal member preform of any of claims 75-81, wherein an outer edge and/or an inner edge of the vehicle frame longitudinal member preform is sealed with the seal (212) to form a closed, airtight, empty interior space of the vehicle frame longitudinal member preform.

85. The vehicle frame longitudinal member preform of claim 84, wherein the seal (212) is a fusion weld, a press weld, an adhesive layer, or a lap joint.

86. A method for manufacturing a vehicle frame longitudinal member, characterized in that the method comprises the steps of:

a) Providing a vehicle frame longitudinal member preform as defined in any one of claims 75 to 85,

b) Sealing the unattached edges of the vehicle frame longitudinal member preform with the seal (212) to form a closed, airtight, empty interior space of the vehicle frame longitudinal member preform,

c) Pressurized fluid is introduced through the valve element (208) into the interior space of the vehicle frame longitudinal member preform to form a deformed vehicle frame longitudinal member.

87. The method for manufacturing a vehicle frame longitudinal member according to claim 86, wherein step c) is performed after introducing at least a portion of the vehicle frame longitudinal member preform between pressure plates (213) such that the pressure plates (213) are in contact with the walls (206, 207) of the vehicle frame longitudinal member preform to introduce at least one flattened area (211) on a portion of the vehicle frame longitudinal member preform.

88. The method for manufacturing a vehicle frame longitudinal member according to claim 87, wherein during step c) forces are applied to the pressure plates (213) in the direction of the vehicle frame longitudinal member preform.

89. The method for manufacturing a vehicle frame longitudinal member according to any one of claims 86 to 88, wherein step b) is achieved by fusion welding, pressure welding, gluing or crimping.

90. The method for manufacturing a vehicle frame longitudinal member according to any one of claims 86 to 89, wherein the fluid is air, water, oil, fluid concrete, fluid plastic or a flowable natural material.

91. A vehicle frame longitudinal member having a longitudinal structure in a side view thereof, the longitudinal structure comprising a front portion (201) oriented towards the front of the vehicle frame and a central portion (202) arranged in the central portion of the vehicle frame, characterized in that the vehicle frame longitudinal member is deformed by a pressurized fluid introduced into its airtight, empty space, which space is formed by an inner wall (206) and an outer wall (207) connected to each other by a corresponding seal (212), wherein a valve element (208) is arranged on at least one of the walls (206, 207).

92. The vehicle frame longitudinal member of claim 91, further comprising a rear portion (203) oriented toward a rear of the vehicle frame.

93. The vehicle frame longitudinal member of claim 91 or 92, wherein the central portion (202) is offset relative to the front portion (201) toward the bottom of the vehicle frame.

94. The vehicle frame longitudinal member of any of claims 91-93, wherein the front portion (201) and/or the rear portion (203) comprises an end loop structure (204).

95. The vehicle frame longitudinal member of any of claims 91-94, wherein a transition region between the front portion (201) and the central portion (202) comprises a transition annular structure (205).

96. The vehicle frame longitudinal member of any of claims 91-95, wherein the central portion (202) comprises a central annular structure (209).

97. The vehicle frame longitudinal member of claim 96, wherein the central portion (202) comprises at least one stiffening rib (210) extending through an opening defined by the central annular structure (209).

98. The vehicle frame longitudinal member of any one of claims 91-97, characterized in that the vehicle frame longitudinal member has inner wall (206) areas and/or outer wall (207) areas with increased thickness of the metal plate.

99. The vehicle frame longitudinal member of any one of claims 91-98, characterized in that it has an inner wall (206) region and/or an outer wall (207) region made of different materials.

100. The vehicle frame longitudinal member of any of claims 91-99, wherein the seal (212) is a fusion weld, a press weld, an adhesive layer, or a lap joint.

101. The vehicle frame longitudinal member of any one of claims 91 to 100, wherein the fluid is air, water, oil, fluid concrete, fluid plastic or a flowable natural material.

102. The vehicle frame longitudinal member of any of claims 91-101, characterized in that the vehicle frame longitudinal member has at least one flattened area (211) on the inner wall (206) and/or the outer wall (207).

103. A body frame comprising connected component members, wherein the component members are at least one side frame as claimed in any one of claims 20 to 30, at least one floor member as claimed in any one of claims 55 to 70, and at least one frame longitudinal member as claimed in any one of claims 91 to 102.