SE1251048A1 - Method of making an outer wall, method of making a reinforced motor vehicle, and the side wall of a motor vehicle. - Google Patents

Abstract

(fiíï) tkåhsiract: íuvemiou 'ra-Wear to a :neahod for produchg as ouïe: vfall, in peuïicnüar a sid-a wall før a motor vehicle (2),iízun arfncarcd smal, eunxprísing fiyenings, a. rocks: pamei cxtesldiwg in 'file bortom: region, a me? rfrzlm-:z area, pilisæs an: :ie placescfiending between 11:e ïoclfcer panel. and 'fl-le moi' fizmflæ area, azaci opening; for reacteiving windows. The 'mv-eniion fauïhef ralate-s ïc-:a meihnrí for producing au :anuared motor valaicle (2) cnmptising an euíer *eaalï made (sf annoteci steei, in paflícuíai' f de w 1ïhat has -Lioofs (12), a ros-ker :nanci exïcndiïlg in ïhß befria-ln zegíoxz, a rofßf iïame ense., píiíars, side places, :md opefiifags m' recei-ving wínzš-'Jxn/s, on a fruit-or vehicle, :said gill-ars, aside pic 'cs *md opening* cxïßndizxg beivveeu the facket: panel and the; roof lífame,are-e.. 'Hae imie11ti0;1 also re tes :o f: side wall for a :not-ar v ch: (Lä), ' ch is :nmic of anwaored steeí and has åoors; (12), a mckerpazacï ex-:euåing in the b-aï m regi , a mo? . ïme area, and pillarß, side and opeuings far rafsiving ævinaïmvs., said pâllars,side pie-Jm, and openings -euendínag bei 'een :he rockar panel and the s-:aoífiame area.

Description

UT lfi Il-e..'.-.J w(fl WO 2011/103861 PCT/DE2011/000176 Method for the production of an onter wall, method for the production of an armored nmtor vehicle, and side wall for a motor vehicle The present invention relates to e method for producing an outer wall, in particular a side wall for a nmtor vehicle, from armor steel, comprising openings, a rocker panel running in the bottom redion, a roof frame region,the pillars extending between the rocker panel and roof frame region, and side parts, as well as openings for the reception of windows.

The invention further relates to a method for producing an armored motor vehicle having an outer wall made of steel, side wall with doors, which side wall in the bottom armor in particular a has on a motor vehicle a rocker panel running region, a roof frame region, pillars eztending between the rocker panel and the roof frame region, side parts, and openings for the reception of windows.

The present invention further relates to a side wall for a nmtor vehicle made from armor steel, oomprising doors, a rocker panel running in the bottom region, a roof frame region,the pillare extending between the rocker panel and roof frame region, side parts, and openings for the reception of windows.Structurally reinforced vehicle side walls, compiledare knownregion, thethe A~The B~pillar The from. a plurality* of individual components, orior art. In the front door from the vehicle side wall consists, for example, of pillar having a rocker panel connection, and the rocker panel are separate components. individual components are produced and heat~treated in part in the hot forming process and must in some ciroumstances fulfill different material thicknesses CONFIRMÄTION COPY lü '.\JCD WÜ 2911/193861 ~ 2 ~ FCT/DE2Ü11/000176 and strength requirements. Following the production of the individual parts, these are joined together by spot welding or gluing to a side wall for a motor vehicle. welding This At the joints, stress peaks can arise. For a oonneotion, material overlaps are necessary, impacts negatively, however, on a low total 'vehicle weight. ln addition, vehicle armorings in which the passenger compartment, and, where necessary, a 'trunk or engine compartment, is hallistically protected against the effect of Warfare are known from the prior art. For the fitting of the vehicle armoring, armoring plates are generally integrated into the original vehicle body.

Thus a door is armored, for example, hy the installation of an armored safety glass and by the insert oh of an armored steel plate into the original vehicle door in the panel region of the door side wall,vehicle with nmthod for a that A drawhaok this oroduotion armoring is the hallistio protection if: created solely by the armored steel plates and. the armored glass, Various door structure components, such as, for or elsethe example, the outer door skin, the door frame the window frame are generally maintained in factory delivery state of the production vehicle, yet often offer no armoring protection. A vehicle door already has a weight of hetween 20 and l5Û kg, which is additionally increased hy the armorinq measures. ln a further known embodiment, vehicle body outer parts are imparted with armored steel plates or replaced by these. These vehicles are artionlarly conspicuous from the outside, since they have angular contonrs. ln addition, the externally applied armoring eohtrihutestwothe directly to a inore solid appearance. in this emhodiment, drawhacks are known. Firstly, it is undesirable for armoring of non~military vehicles to be i..)LT: ins)in WO 2011/103861 ~ 3 ~ PCT/DE2011/000176 apparent and, eecondiy, retrofittef armoring componentswhich have heen externally applied are imprecieelyehaped. lt is speoifically, however, the transitionalregions from, for example, the doore of the ve icl. tothe connecting regions of the body which ar, ofparticular importance for hallistic protection. In theevent of inadeguate covering, pressure waves can heremake their way into the interior and thue inflict injury on the paesengers.

The object of the present invention is therefore 'toprovide a :method with which en armcring' cf' a motorvehicle is matched particularly well to the entercontour of the motor vehicle, combined withsimultaneous high hallietic protective effect. It isalso an object of the present invention to provide amotor vehicle armoring, ae well ae ¿1 method. for theproduction of the same, which has a particularly high dimensional accuracy.

The aforementioned object ie achieved according to theinventioh_ with_ a method for _prodncing“ an outer wall according to patent claim 1, The aforementioned object ie further achieved hy amethod for producing an armored motor vehicle according to patent ciaim 9, The material part of the object ie achieved hy a sidewall for a motor vehicle made of armor steel and having doors, according to patent claim 12.

Advantageoue refinemente of the inventive concept are a constituent part of the dependent patent claime.

A particular advantage with the inven ive method for producing a nwtor vehicle armored outer wall ie that ï-J(I: fx a) Lu(j: WO 2011/103861 ~ 4 ~ PCT/DE2011/000176 the totel weight of the vehicle is reduced, while the bellistic protective effect is the same end/or improved. in addition, cost savings are achieved in the production method, since complex integrations into pre~existing structures of vehicle bodies are elimineted_ The particular dimensional stability of the gap widthswall ballisti, in a vehicle outer enhsnces, in turn, the effects of Warfare.equippecwalls produced with e method according to the invention protection. against Moreover, motor vehicles which ere with outer are not in the panel region exterhelly identifiabie es protection vehicles. ïnventive side walls made of armor steel additionaliy increase the rigidity' of the total body. This is of particular the case of bellistic importance in very strong effects, such as, for example, explosive charges. A “totel_ deformation. to the detriment of the pessenger compartment ie very largely avoided, The bod; structure of the motor vehicl is reinforced with the outer walls according to the invention against the deformation effect of werfare.

The inventive method for producing an outer wall, in particular a side wall for e motor vehicle, from armor steel, rooker panel running in the bottom extending between the rocker comprising openings, a region, e roof frame region, pillars panel and the roof frame region, and side parts, is cherecterized by the following method steps:the outer the outer Contour of ~ provision of a pressing tool for the forming of en outer wall hisnk having this outer oontour, WO 2011/103861 e 5 ~ PCT/DE2011/000176 e forming of the outer wall blank from an armor steel metal sheet, and ~ outting out of the doors and openings from the outer wall blank.

(Jï This offers the advantage that the outer oontour of theouter wall of the motor vehicle can he identioallyreprodnced with the armored outer wall. Consequently, al0 difference relative to the original production vehicle is not deteotahle from the outside.

Froni the derived. outer oontour“ of 'the outer wall isderived a suitable tool geometry, allowanoe being madel5 for the degree of shrinkage during" the hot forminq.From this, a pressing tool for forminq an outer wallblank having the outer oontour can be provided.According to the purpose of use, this pressing tool oanhot form various proteotive materials from temperature 20 ranqes above AC3 into the desired shape. The Various proteotive materials are respeotively, in the form of an armor steel metal sheet, reshapefl into ah outer wallblank. 25 For the production, a suitable tool geometry and acorreaponding 'tool design .mustt he providedi with dueregard to suitable tool materials. Partioularimportance is attached to the large heat quantity ofthe armor steel metal sheet. These have antioipated 30 sheet weights rangihg between lÛO and. 5ÛÛ kg. It ienecessary to ensure that the heat is reliably evacuatedfrom the sheet metal and the tool, so that hardeninq is possible in the forming tool.

Br ln a further method step, it is provided that doors andopenihgs, as well as openings in the doore, are out out of the outer wall blank. A particularly* good (Jl m~ 1 WÜ 2011/193861 ~ 6 ~ PCT/DE2Q11/000178 dimensional stahility is herehy attainahle.

Cohsequently, a small gap width ehsues.ln a preferred emhodiment, the outer contour is defined hy determination. of“ the original lnotor vehicle outerundertakeh ohfor also contour. The determination can here hethe hasis of CAD data,the possible for a point cloud to be generated, which are directlv provided, example, by vehicle manufacturer. It is which point cloud is then ascribed to a surface area. Furthermore, determination of the outerthe The optical derivatioh can be generated hy within_ the structure, an optical derivationo of original outer contour is conoeivahle. or complete redesign. the heam cutting out of the openings is realired by laser cutting or water jet cutting, As a result, ¿a particularly dimehsional highthe advantage of stability“ ofthe laser beam or the openings relative to cutouts produced hy cutting ensues. A further water jet cutting is that, in the course of th, nenufacturihg process, a press hardehing operation is applied, wherein the outer wall blank is already heat~ treated before the openinqs are out out, The cutting methods of the laser heam cutting or water jet cutting't%1e structural transformations at that keep the cutting sites low, so the ballistic protection capability of the therehy produced sheet metal components is not impaired. n addition, it would also he possible within the ecope of the invention to produce the openihgs hy punching during the production operation. hinges and openingthe ln a further construction variant, means are coupledo to the generated. cutouts and the outerthe with cutouts are arrahged ae doors and flape in doore and here The wall. The ílaos are formed b"h 3 eutouts. cutouts themselves are provided lO WO 2011/103861 ~ 7 er PCT/DE2011/000176 hinges in the form ofhandles,wall. As a in the f or opening hraokets, for example door and are arranged, once again, in the outer result of the previously produced cutouts .in of the doors, a particularly high “ordimensional stahility is ensured between the outer walland the T determined by the cuttihg out process. doors, he gap width is here suhstantially Possihle warping of the components by a downstream heat~treatment orooess is eliminated in the method according to the i ihvention.

The fitting of the hinges and opening means can here be reali:ed_ in. an integrally' honded, form~fit or foree~ looking connection, The oonneoti n of, for example, window frames, r else door inner panel parts, should also be construed within the scope of the invention.

In a particularly preferred embodiment, the gap widthsare oonfigured sowith formed between doors an: outer wall as to he ballistioally secure by ooupling respeetively cireumferential overlaps, The overlap can here be realized, for example, in the form of a stop or a circumferential weld on plate or similar. The fitting of the stop can take place from outside or else from inside. The attachment oan he made to the door or to the side wall. lt is particularly heneficial that the fitting of the overlap can be realized individually in aooordanee with the different armoring level requirements. ln the oase of high antioipated hallietic pressure effects resulting from explosive Warfare, for example, the fitting of an overlap from the outside is whereas, in the case of a low levelfitted from the an appearance of the production vehicle thus advantageous, of armoring, the overlap can be inside, so that which is as true to the original as possible is maintainef.

UT UGCP WC 2011/103861 ~ 8 ~ FCT/DE2Ûl1/990176 Within the soope of the inveiti=n, the production of the outer wall blank can he reelized hy means of hot forming or hy cold forming. The forming operations are in the form This a heat treatmentwall blank. the hot respeotively followed hyof the for example, in of hardening outer can he realized torminr orocess hfå' _ .. guenohing in az tool clamping* systenï or else hy* cold forming with subsequent heat treatment. This gives the advantage that, according to the material used, the heat treatment process can bethatachieved and an optimal hardening, of the individually tailored thereto, so optimal forming conditions are and thus protectivearmored material is in_ line effect, adjusted with the respective requirement profile.

The present invention further relates to a method forwallwith producing en armored motor vehicle having an outer made of armor steel, int particular a side wall doors, which side wall has on a motor vehicle a rooker panel running in the bottom region, a roof frame region, the pillare extending between the rocker panel and roof frame region, and side parts, said .method eomprising th. following method steps: M- removal of the original vehicle onter wall, e arrangement of the outer wall of armor steel on the motor vehicle, and ~ coupling of the outer wall to the motor vehicle. that the the produced nmtor This gives the advantage original vehicle outer wall is replaced hy vehicleT armored outer wall, in terms of the 'vehiole,s nnece sary weight which would accrue, for example, the standar integrated with The frmn sheet metal outer wall armored steel plates is eliminated. (fi P1(f: \1(J: 'io-Jl WO 2011/103861 ~ PCT/DE2011/000176 onter wall of armor steel is thus optimized with regardthe 'tlle to the weight distribution and also weight, Furthermore, an outer wall oroduoed with 'method invention can he optimally integratedIn the according to theas well the onto and into the vehicle. roof region, as in the nnderhody region, it can he coupled to wherein in the roof region and underbody Within vehicle, further introduoed. the the armorings are the region soope of ihvention, roof or underhody region itself can also he produced with the invehtive method for producing an outer wall.

Preferably, the enter wall is ooupled to original Through oreoiee .L oonneotihq points of the motor vehicle. ripping out of the unarmored outer wall, it is possible to produce the connecting region directly with standard conneeting points and the armored outer wall. This offers, in particular, the advantage that the rigidity of the vehicle body, hy the retrofitting of an armored outer wall on the original oonnectihg points, remains equal to the ,roduction vehicle, or is enhanced hy the a rmored ooznpon ent . ln a further emhodiment, the onter wall is ooupled in a roof region, in a floor region and/or in front regions to additional armored steel plates which are monnted onthe motor vehicle for the armoring of the regions. Thetheof the hallistic protection, on the other the the additional ooupling offers on one hand an enhancement hand an enhancement of rigidity of total vehicle body.

The present inventioh further relates to a side wall for a lnotor vehicle made of armor steel, eomprising doors, a rooker panel running in the bottom region, a roof frame region,the pillars extending between the rooker panel and roof frame region, and side parts, lO WD 2011/193851 ~ lG e FCT/EE2Ûll/GOG176 characterized in that the side wall is produced in one viece from an armor steel metal sheet and the doorsi and openings are then out out of the produced snaped part, In a particularly preferred embodiment, the side wall has a lhardness between. ÉGÛ and. BÜO Brinell. hardness, The ariored side wall which is thus produced offers, in particular, protection against warfare in the form of explosive charges and also in the form of projectiles, According to the used armored material and user requirement profile, or the required level of armorinq, said side wall must expediently be tailored to the wishes of the respective vehicle manufacturer or customer with a production method within the scope of invention. the ln another preferred emhodiment, a gap, surrounding the doors, between the door and the side part is designed to be ballistically secure hy virtue of additional coupled covers. Pressure waves can hence penetrate through the geps into the protected compertment only in reduced form. As a result of connections with sealing profiles, the protected. compartment can be protected against nuclear, bacteriological and chemical Warfare.andthe 'tlie Further advantages, features, characteristics aspects of the present invention emerge from following description, preferred embodiments on basis of the schematic drawings. These serve for easier understanding of the invention, wnerein: figures la~ld. show an inventive method, for producing an ermored outer part; G h) ba.)(f) WO 2011/103861 ~ ll ~ PCT/DE2011/000176 figure 2 shows a seotional view of a transitionalregion of the onter wall to a door with overlap, and i-'h igure 3 shows an inventive construction variant of an armored side part with doors.

In the figures, the same reference symhols are used forsame or similar parts, wherein oorresponding oroomparable advantages are achieved even if a repeateddescription ie dispensed with for reasons of simplifioation, kr), Figures la to ld show an inventive method for produoinian outer wall l of an armored motor vehicle 2. in afirst step, an. outer* Contour 3 of the armerad :notorvehicle 2 ir; determined. In ifina determination eif theouter Contour 3, rooker panela 4, a roof frame region5, various pillars 6, such as, for example, the A, Band C pillar of a side part 7 of an armored .motorvehicle 2, are determined. following this, openinqs 8are fixed in the side wall of the armored motor vehicle2. With the thus determined data, a pressing tool (notdetailed here) is provided. In the pressihg tool, anarmor steel metal sheet is formed into an outer wallblank 9. This is represented in figure la. ln a secondstep, cutonts 1O are generated in the outer wall blank9, The outouts 10 are generated at the sites at whichopenings Eš are intended to lm: formed. The openings 8can be oonfigured, for example, in the form of a windoweutout ll, or else a door 12, The doors 12 themselves can, in turn, have window cutouts ll. in a third_ method step, the ont~out doors 12 areprovided with hingee 13 and further opening means 14,The coupling to a window frame region (not referred to in detail here), or else to inner panel çarts, should 4.31 D.)(Jï WC 2011/163861 ~ 12 ~ PCT/DE2Û1l/ÛOG176 also be oonstrned, for example, es an element of theinvention. in a fonrth step, represented in figure ld,the doors 12 conpled to the hinges 13 and opening means14 are, in turn, inserted into the side part 7. To thisend, the doors 12 with the hinges 13 anda with theopeningi means 14 are connected to the side wall atooupling points (not shown here due to the sohematiodrawing}. ?artiou1ar1y advantageously, in the methodaccording to the invention, an optimal minimal gap width 15 hordering the doors 12 is obtained, in figure 2, the transitional region of the side part 7to a door 12 with an overlap 16 is represented. It isnarticularly evident that a ïninimal gap width 15 isoonfigured between the door 12 and the side part 7. Theoverlap 16 offers, on the one hand, supplementaryhallistic protection, on the other hand, however, alsoa stop facility for the door 12. The overlap 16 canhere he ooupled in a oonneoting region to the door 12,ori else, as represented_ here, to the side wall. 'ïheooupling is preferahly realized in an integrally hondedconnection, but can also be realized in form~fit andforforceelocking connection. There is also the option offitting a seal oircumferentia11y to the door 12 in theregion of 'the oonneetinq region. 17. *Fhe seal 18 can also, however, be fitted to the overlap 16, Figure 3 shows en inventive construction variant of anarmored vehicle outer wall 19 with doors 12. Thevehicle outer wall 19 is produced with the inventivenæthod for producing en armored outer wall with doors12, and is conpled to the armored motor vehicle 2 atfaotory~made conneoting points 20. The coupling is hererealized in a roof reäion 21, in a floor region 22 and in a front region 23. At the resoeotive coupling regions, the motor 'vehicle 2 ,an he rei foroed twith additional armor steel plates 24.

WO 2011/103861 Reference symbols: fiflßwNi-Q 1314161?18192G21222324 outar armoræd motor vehicle outær rockerroof fpillarside popeninoutar cutoutwindowdoor hinge openingap wioverla wallContourpanel rama regionart Q wall blank outout g meansdt h P connecting region Sealvehicl COIIIIÉECI e outar wall ting point roof region floorfront Ei lfïíïfi BC regionregion steel plate PCT/DE2011/000176

Claims (4)

'-1 (A)(JT WO 2011/103861 »-14 ~ PCT/DE2Û1lfGÛ0176 Patent claims i. A method for producing an outer well (1), in particular a side wall for a motor vehicle (23,

1. \ from armor steel, oomprising opehinge (8), arooker panel (4) running in the bottom region, eroof frame region (5), pillers (6) extendingbetween the rocker panel (4) and the roof frameregion ( and side parts (7), oomprieing the 5Ã\Vi!following method steps: -« definition of the outer oontour (3) of the outerwall (1), W provision of a pressihg tool for the forminq ofen outer well blank having this onter Contour(3), ~ formihg of the outer wall blank (ä) from an armor steel metal sheet, and ~ outting out of the doors (12) and opehings (8) from the outer wall blank (>). aimed in oiaim 1, oheraoterized in

2. * The method es oithat the ont: r oontour (3} ie defined_ bydeterminetion of the original motor vehicle onter COII .C11 .

3. The method_ ae oleimed in claini l or 2,oharacterizeo_ in that the outer Conton* (3) ieopticeliy modeied on the motor vehicle onteroontonr, and/or in that the onter oontonr (3) is redeeigned. 4@ The method es cflaimed in one of claims l to 3, - 1 characterized in that the cutting out of the (JTH lO u.)<3 WO 2011/103861 ~ 15 ~ PCT/DE2011/000176 openings (8) ie realízed by laser heam ontting or water jet cutting. The method ¿fis claimed ÅJ1 one cüf claims 1. to 4, characterized in that (13) and(143 and the outoute hinges opening(193 (12) in means are coopled cutoutsílÛ} (1). to generatedare arranged as doorsthe outer wall F. of olaime 3. to 3, widths (15) The method ens olaimed il: one characterized in that the gap formed(l2) and to be ballistioally between doore ooter wall (l) are nfignref ao ae secure hy 1 ocouoling to reepeotively oircumferenti.i overlape1 The method ae olaimed in one of ciaims l to ih oharaoterized in that the production of the outerwall blank (9) is realized by means ot hot formingor hy cold forming, with eubsequent hardening. The method ae olaimed in one of cflaims l to V,oharaoterized in that the outer wall blank (9) ishardeneá in the preeeing tool. vehicle .A Inethod. for producing an armored_ motor (2) having en outer wall (1) made of armor steel,'axïšíll motor vehicle a in particular a side with doors (lå), which side wall has on a rockar panel (4) running in_ the bottom: region, a roof frame region (5), llare (6} extending between the l. rocker panel (4) and the root frame region (5), (Vlšf following method steps: and. side parts said method oomprieing“ the ~ removal of the original vehicle outer wall ...x(lf: WO 2011/103861 ~ 15 ~ PCT/DE2011/000176 ~ arrangement of the enter wall of armor steel on the motor vehicle, and =- eoupling of the enter' vall fl) to the .motor 5 vehicle. lO. The method as claimed in claim 9, eharaeterized inthat ithe enter' wall (l) ie eoupled te originaleonnecting points of the motor vehicle, ll. The lneth d ae claimed, in elaina 9 er lß,eharacterized in ïhat the side wall is coupled ina roof region (21), in a floor region (22) andfor in front regions (23) to additional armor steel ;5 platee (24), which are monnted en the motor vehicle for the armerinq of the reqiene, ”I” 1”.LLQ 1. side wall for a motor vehicle made of armor kv steel, comprising doors (12), a rocker panel (4) 20 running in the bottom region, a roef frame region (T), pillers (6) extendinq between the recker panel (4) and the roof frame region (5), and side arta (?) characterized in that it is eroduced inP i one piece from en armor steel metel sheet, and the 25 doora (l2) and openings (8) are then out ent of the produced Shaped part. l3. The side wall ae elaimed in elaim 12, oharacterized iii that it kun; a hardnese between .O 300 and 890 HB, Ul-(JF. 'ä l

4. The side wall e elaimed in elaim le er l3, QJ eharaeterized in that a gap, surrounding the deors(12), between the door (12) and the side part (7)is designed to be balliatically secure by virtue of additionally coupled covers,