DE102022125461A1 - Side impact beam for a motor vehicle door, manufacturing method and motor vehicle door with such a side impact beam - Google Patents

Abstract

The invention relates to a side impact beam (30) for a motor vehicle door (10), which is designed as a sheet metal part. The side impact beam (30) has a triple U-profile with five plateaus in cross section, namely with a central first plateau, which is followed on both sides by two plateaus connected by flanks, with the two laterally outer plateaus merging into a first leg (308) and a second leg (311). The invention further relates to a method for producing such a side impact beam (30) by press hardening, as well as to a motor vehicle door (10) which has such a side impact beam (30).

Description

The invention relates to a so-called side impact beam for a motor vehicle door, wherein this side impact beam is designed as a formed sheet metal part. The invention further relates to a method for producing such a side impact beam and also to a motor vehicle door with such a side impact beam.

A side impact beam in question is a component that is permanently installed or is to be installed in a motor vehicle door and is intended to reduce intrusion into the passenger compartment in the event of a side impact, particularly in the area of the door center panel. Such a side impact beam can be designed as a sheet metal part, particularly made of high-strength sheet steel material.

From the nearest one DE 10 2020 005 898 A1 a side impact beam for a motor vehicle is known. The side impact beam has a cross-section that is essentially W-shaped (which is essentially a double U-profile), with a first plateau and a first flank extending laterally therefrom and a first flank opposite the first flank and also laterally from the first Plateau departing second flank. The first flank continues into a second plateau, which in turn merges into a first leg. The second flank in turn merges into a third plateau, which in turn merges into a second leg. The side impact beam is expediently made of press-hardened steel.

The state of the art is also referred to in the DE 43 40 033 C2 , DE 102 12 792 B4 , DE 102 56 137 B3 , DE 196 54 376 B4 and EN 10 2015 015 398 A1 pointed out.

The invention aims to provide a side impact beam that is significantly more resilient than a side impact beam with a W-shaped profile.

This is achieved with the side impact beam according to the invention of patent claim 1. With subordinate patent claims, the invention also extends to a method for producing a side impact beam and to a motor vehicle door with a side impact beam. Advantageous further developments and refinements of the invention result accordingly for all subject matter of the invention from the dependent patent claims, the following description of the invention (this expressly also includes features described as examples, options and alternatives) and the drawing.

The side impact beam (SAT) according to the invention has a triple U-profile in cross section with five plateaus, namely with a central first plateau, which, in particular in relation to a transverse direction (see below), is followed on both sides by two plateaus connected via flanks, whereby the two plateaus on the outside merge into a first (outer or external) leg and a second (outer or external) leg.

It has been found that a triple U-profile, which can also be referred to as a double W-profile, has a significantly higher load capacity than a conventional W-profile, especially without any significant additional weight. In addition, compared to a W profile, there are also further degrees of freedom that can be used for optimization, so that the side impact beam according to the invention can be adjusted and optimized even better with regard to its protective and crash properties.

The side impact beam according to the invention preferably has a longitudinal direction and is at least in a central axial longitudinal section with a corresponding cross section, i.e. H. with the triple U-profile. In particular, a cross section that remains essentially the same or changes only slightly over the axial extent is provided. At the axial ends, which are provided in particular for fastening the side impact support in the motor vehicle door, the triple U-profile can taper off or flatten.

The terms "plateau" and "flank" used to describe the invention, as well as the features and explanations that refer directly or indirectly to them below, are primarily directed to a consideration of a two-dimensional cross section of the side impact beam that runs essentially perpendicular to the longitudinal direction of the side impact beam. With respect to such a cross section, a lateral direction or transverse direction and a vertical direction can be defined, as shown in the drawing.

The triple U-profile of the side impact beam according to the invention has five plateaus which are connected via so-called flanks, which means in particular that two adjacent plateaus are laterally connected to one another via a flank. A plateau can be viewed as a vertex or vertex surface. The five plateaus are arranged next to each other in the lateral or transverse direction, with the first plateau being the middle plateau between the other plateaus and can therefore also be referred to as the central plateau.

Analogous to the EN 10 2020 005 898 A1 According to the terminology used, it is preferably provided that the first plateau merges into a second plateau via a first flank and merges into a third plateau via a second flank opposite the first flank, the second plateau merges into a fourth plateau via a third flank opposite the first flank and the fourth plateau merges into the first leg opposite the third flank, and the third plateau merges into a fifth plateau via a fourth flank opposite the second flank and the fifth plateau merges into the second leg opposite the fourth flank.

Preferably, the first leg extends over a (laterally) outwardly angled first flange and the second leg extends over a (laterally) outwardly angled second flange.

Furthermore, it is preferably provided that the fourth plateau and the fifth plateau, in particular together with the first plateau, are at the same first level and/or that the second plateau and the third plateau are at the same second level. However, it can also be provided that each plateau is at a different level.

Furthermore, it is preferably provided that the first plateau (in the lateral direction or in the transverse direction) is wider than the other plateaus. This means that the first plateau is the widest of the five plateaus.

Furthermore, it is preferably provided that the triple U-profile is mirror-symmetrical with respect to an (imaginary) center line running through the first plateau, as shown by way of example in the drawing.

The side impact support according to the invention is preferably formed, in particular in one piece (i.e. from a piece of sheet metal), from a hot-formed and/or press-hardened steel sheet material. The press-hardened steel sheet material can, at least in some areas, have a strength of at least 1500 MPa. The steel sheet material used can have a sheet thickness of 1.3 mm to 2.4 mm, preferably of 1.8 mm to 2.3 mm and in particular of 2.0 mm or essentially 2.0 mm. Furthermore, a corrosion protection coating, in particular galvanizing, can be provided.

• - Ausformen und Presshärten der Plateaus sowie der Flanken, wobei der erste Schenkel und der zweite Schenkel als abstehende bzw. abragende Flügel vorgeformt werden;
• - anschließendes Umbiegen der Flügel, was auch als Einklappen aufgefasst werden kann, wodurch der erste Schenkel und der zweite Schenkel in ihre endgültige Lage gebracht bzw. gebogen und gegebenenfalls auch nachgeformt werden.

The method according to the invention for producing a side impact beam made of press-hardened sheet steel material, which, according to the preceding explanations, has a triple U-profile in cross section with five plateaus connected by flanks as well as a first leg and a second leg, comprises the following steps:

• - forming and press hardening the plateaus and the flanks, whereby the first leg and the second leg are pre-formed as protruding wings;
• - subsequent bending of the wings, which can also be regarded as folding, whereby the first leg and the second leg are brought into their final position or bent and, if necessary, reshaped.

The production is carried out starting from a circuit board made of a steel sheet material suitable for press hardening, whereby a tailor-made circuit board, i.e. H. a so-called tailored blank, in particular a tailored rolled blank, can be used. The board can first be heated to austenitizing temperature and then formed in a press hardening tool and press hardened at the same time (so-called direct press hardening). Alternatively, the board can first be preformed, then heated to austenitizing temperature and then reshaped and press hardened in a press hardening tool (so-called indirect press hardening). Press hardening as such is known from the prior art, for which reference is made to the relevant specialist and patent literature.

On the one hand, the side impact beam to be produced has a triple U-profile, which is much more difficult to form than a conventional W-profile. On the other hand, the shaping is limited in press hardening, in particular in direct press hardening, and the same also applies to hot forming (see below). The method according to the invention therefore provides that the shaping or forming process comprises at least two steps, whereby first the inner or middle profile area is formed and press hardened, in particular in a drawing process (using a press hardening tool), and then a further forming or bending step is carried out in which the outer profile area is completely formed. A separate forming or bending tool is preferably used for the further forming or bending step. Bending can take place when the material is warm or still warm (i.e. not yet completely cooled down), and local heating of the bending zones can also be provided. Bending can also take place when the material is cold or cooled down.

During press hardening, the entire side impact beam is preferably press hardened. All However, the bending zones in which the wings are bent can be left soft during press hardening or not or only slightly hardened. The bending zones can still be made soft or softened even after press hardening. The former can be accomplished, for example, by locally heating the press hardening tool. The latter can be done, for example, by means of local laser beam heating of the previously press-hardened steel sheet material, whereby the bending can take place immediately afterwards, i.e. while still in the heated state. The steel sheet material then has a higher ductility locally in the area of the bending zones. This can then also have an advantageous effect on the crash performance of the side impact beam and counteract unfavorable crack formation.

Analogous to the previous explanations, conventional hot forming (without press hardening) can also be provided as an alternative to press hardening. The subsequent bending of the wings can then take place when they are still warm or when they are cold or cooled down.

The motor vehicle door according to the invention, which is in particular a side door, has a side impact support according to the invention and/or produced according to the invention. Preferably, only a single side impact beam is provided for the motor vehicle door, which is absolutely sufficient due to its high load capacity. The side impact support is preferably fastened by screwing and/or welding to the bodyshell structure of the motor vehicle door.

• 1 zeigt eine Kraftfahrzeugtür mit einem erfindungsgemäßen Seitenaufprallträger.
• 2 zeigt den Seitenaufprallträger der 1 im Querschnitt, gemäß dem in 1 angegebenen Schnittverlauf (A-A).
• 3 veranschaulicht schematisch in einer Querschnittsdarstellung analog zur 2 die erfindungsgemäße Herstellung des Seitenaufprallträgers.

The invention will now be explained in more detail in a non-limiting manner with reference to the drawing. The features described and/or shown in the drawing can be general features of the invention, even detached from specific combinations of features, and can further develop the invention accordingly.

• 1 shows a motor vehicle door with a side impact beam according to the invention.
• 2 shows the side impact beam 1 in cross section, according to the in 1 specified cutting course (AA).
• 3 illustrated schematically in a cross-sectional view analogous to 2 the production of the side impact beam according to the invention.

In the 1 Motor vehicle door (side door) 10 shown without outer panel has a side impact beam 30 which is attached to the shell structure 20 of the motor vehicle door 10. The side impact support 30 is manufactured as a one-piece and in particular press-hardened sheet metal part. The side impact beam 30 has a longitudinal direction L and is designed in cross section with a triple U-profile, as shown below with reference to 2 explained.

For the 2 From the cross-section AA shown with a triple U-profile, a transverse direction or profile transverse direction Q, i.e. a lateral direction, and a vertical direction or profile vertical direction H can be determined. As can be seen from the cross-sectional view, the side impact beam 30 has a central first plateau 301. The first plateau 301 merges via a first flank 302 into a second plateau 303 and via a second flank 304 (directly) opposite the first flank 302 into a third plateau 305. With respect to the transverse direction Q, the first flank 302 and the second flank 304 are (directly) opposite each other and with respect to the vertical direction H, the second plateau 303 and the third plateau 305 are opposite the first plateau 301.

The second plateau 303 merges via a third flank 306 into a fourth plateau 307 (located laterally or in the transverse direction Q on the outside) and the fourth plateau 307 merges into a first (outer) leg 308. With respect to the transverse direction Q, the third flank 306 is (directly) opposite the first flank 302 and the first leg 308 is (directly) opposite the third flank 306. With respect to the vertical direction H, the fourth plateau 307 is opposite the second plateau 303.

The third plateau 305 merges via a fourth flank 309 into a fifth plateau 310 (outside laterally or in the transverse direction Q) and the fifth plateau 310 merges into a second (outer) leg 311. With respect to the transverse direction Q, the fourth flank 309 is (directly) opposite the second flank 304 and the second leg 311 is (directly) opposite the fourth flank 309. With regard to the vertical direction H, the fifth plateau 310 lies opposite the third plateau 305.

The first flank 302 and the second flank 304 each extend laterally from the first plateau 301 and each lead laterally into the second plateau 303 and the third plateau 305, respectively. The same applies analogously to the third flank 306 between the second plateau 303 and the fourth plateau 307, as well as to the fourth flank 309 between the third plateau 305 and the fifth plateau 310.

The first leg 308 extends over an outwardly angled or outwardly projecting first flange 312 and the second leg 311 extends over an outwardly angled or outwardly projecting second flange 313. The two flanges 312, 313 are with their free end directed away from the first flank 302 and the second flank 304.

It is also provided that the cross section or the triple U-profile is designed to be mirror-symmetrical with respect to a center line M running in the vertical direction H through the first plateau 301. Furthermore, it is provided that the first plateau 301, the fourth plateau 307 and the fifth plateau 310 are on the same or the same first level N1 and that the second plateau 303 and the third plateau 305 are on the same or the same second level N2. It is also provided that the first plateau 301 is wider (in the lateral direction or with respect to the transverse direction Q) than the other plateaus 303, 305, 307, 310 and that the laterally (i.e. in the transverse direction Q) outer plateaus (i.e. the fourth Plateau 307 and the fifth plateau 310) are wider than the inner plateaus (i.e. the second plateau 303 and the third plateau 305).

Self-explanatory, the plateaus, flanks, legs and flanges described in relation to the cross section extend in the longitudinal direction L of the side impact beam 30, so that the side impact beam 30 has corresponding surfaces or surface sections. At the axial ends of the side impact beam 30, the triple U-profile can taper off or flatten, as in 1 shown.

3 illustrates a preferred method of manufacturing the side impact support 30. As described above, it is provided that the plateaus 301, 303, 305, 307, 310 and the connecting flanks 302, 304, 306, 309 are first formed and in particular press-hardened, with the (outer) legs 308, 311 are preformed together with the flanges 312, 313 as laterally outwardly projecting wings 308 ', 311', in particular as lateral extensions of the outer plateaus 307, 310. These wings 308 are then bent over, as illustrated by arrows B ', 311' (and possibly also reshaping) whereby the legs 308, 311 together with the flanges 312, 313 are brought into their final positions. In order to simplify this bending B, the steel sheet material in the bending zones Z can be left soft during press hardening or can be softened or softened after press hardening.

LIST OF REFERENCE SYMBOLS

10

Motor vehicle door

20

Shell structure

30

Side impact beams

301

first plateau

302

first flank

303

second plateau

304

second flank

305

third plateau

306

third flank

307

fourth plateau

308

first leg

308'

first wing

309

fourth flank

310

fifth plateau

311

second leg

311'

second wing

312

first flange

313

second flange

b

Bend over

H

Vertical direction

L

Longitudinal direction (longitudinal axis)

M

Centerline

N1

first level

N2

second level

Q

Transverse direction

Z

Bending zone

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102020005898 A1 [0003, 0012]
• DE 4340033 C2 [0004]
• DE 10212792 B4 [0004]
• DE 10256137 B3 [0004]
• DE 19654376 B4 [0004]
• DE 102015015398 A1 [0004]

Claims (10)

Side impact beam (30) for a motor vehicle door (10), which is designed as a sheet metal part, characterized in that the side impact beam (30) has a triple U-profile with five plateaus (301, 303, 305, 307, 310) in cross section, with a central first plateau (301), which is followed on both sides by two plateaus (303, 305, 307, 310) connected via flanks (302, 304, 306, 309), wherein the two laterally outer plateaus (307, 310) merge into a first leg (308) and a second leg (311). Side impact beam (30) after Claim 1 , characterized in that the first plateau (301) merges into a second plateau (303) via a first flank (302) and merges into a third plateau (305) via a second flank (304) opposite the first flank (302), the second plateau (303) merges into a fourth plateau (307) via a third flank (306) opposite the first flank (302) and the fourth plateau (307) into the first leg (308) opposite the third flank (306), the third plateau (305) merges into a fifth plateau (310) via a fourth flank (309) opposite the second flank (304) and the fifth plateau (310) into the second leg (311) opposite the fourth flank (309), skip. Side impact support (30). Claim 2 , characterized in that the fourth plateau (307) and the fifth plateau (310) are on the same first level (N1) and/or that the second plateau (303) and the third plateau (305) are on the same second level level (N2). Side impact beam (30) according to one of the preceding claims, characterized in that the first leg (308) extends over an outwardly angled first flange (312) and the second leg (311) extends over an outwardly angled second flange (313). Side impact support (30) according to one of the preceding claims, characterized in that the first plateau (301) is wider than the other plateaus (303, 305, 307, 310). Side impact beam (30) according to one of the preceding claims, characterized in that the triple U-profile is designed to be mirror-symmetrical with respect to a center line (M) running through the first plateau (301). Side impact beam (30) after Claim 1 or after one of the Claims 2 until 6 , characterized in that it is formed from a press-hardened sheet steel material. Method for producing a side impact beam (30) according to Claim 7 , comprising the steps of: - shaping and press hardening the plateaus (301, 303, 305, 307, 310) and the flanks (302, 304, 306, 309), wherein the first leg (308) and the second leg (311) are preformed as protruding wings (308', 311'); - subsequent bending (B) of the wings (308', 311'), whereby the first leg (308) and the second leg (311) are brought into their final positions. Procedure according to Claim 8 , characterized in that the bending zones (Z), in which the wings (308', 311') are bent over (B), remain soft during press hardening or are made soft after press hardening. Motor vehicle door (10) comprising a side impact beam (30) which is designed according to one of the Claims 1 until 7 trained and/or with the procedure according to Claim 8 or 9 is manufactured.

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