WO2007084120A1 - Panneau avant et soubassement formés d'une seule pièce par laminage pour ensemble carrosserie autoporteuse de véhicule - Google Patents

Panneau avant et soubassement formés d'une seule pièce par laminage pour ensemble carrosserie autoporteuse de véhicule Download PDF

Info

Publication number
WO2007084120A1
WO2007084120A1 PCT/US2006/001616 US2006001616W WO2007084120A1 WO 2007084120 A1 WO2007084120 A1 WO 2007084120A1 US 2006001616 W US2006001616 W US 2006001616W WO 2007084120 A1 WO2007084120 A1 WO 2007084120A1
Authority
WO
WIPO (PCT)
Prior art keywords
panel
box assembly
roll
width
upright
Prior art date
Application number
PCT/US2006/001616
Other languages
English (en)
Inventor
Frank G. Mcnulty
D. James Zimmerman
Michael Lund
Original Assignee
Pullman Industries, Inc., A Corporation Of The State Of Michigan
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Pullman Industries, Inc., A Corporation Of The State Of Michigan filed Critical Pullman Industries, Inc., A Corporation Of The State Of Michigan
Priority to PCT/US2006/001616 priority Critical patent/WO2007084120A1/fr
Publication of WO2007084120A1 publication Critical patent/WO2007084120A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/20—Floors or bottom sub-units
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D33/00—Superstructures for load-carrying vehicles
    • B62D33/02—Platforms; Open load compartments

Definitions

  • This invention relates to a box assembly for a vehicle, such as a pickup truck, and more specifically to an improved construction of a vehicle box assembly employing at least one unitary and monolithic roll-formed panel which has alternating parallel grooves and channels extending in the lengthwise direction and which after roll-forming is transversely bent through a substantially 90° angle to define a main horizontal part having a width which extends generally at least between the wheel wells of the vehicle box assembly so as to function as the load-bearing bed, and which horizontal part joins through the 90° bend to an upright part which is of corresponding width and projects upwardly to define at least a significant width of the upright front wall of the box assembly.
  • This invention also relates to the method of constructing a vehicle box assembly employing a monolithic one-piece roll-formed panel which functions to define both the upright front wall and the bed of the box.
  • the upwardly-opening box assembly associated with vehicles such as pickup trucks and the like have, for many years, employed a large plurality of stamped metal panels for defining the box.
  • the front and side panels of the box are stamped sheet steel members, and in most instances the bed of the box is also defined by one or more stamped sheet-like steel panels.
  • Forming the box predominantly from stamped sheet steel panels results in structural and economic factors which are less than desirable.
  • a principal disadvantage associated with using stamped sheet steel panels is the fact that such panels require use of a greater quantity of material than is optimally desired, and also ultimately results in the formed members having greater weight than desired, both of which are undesirable from the standpoint of the overall vehicle.
  • stamping involves forming a three-dimensional shape from a flat sheet steel of rather thin gauge, and during stamping the three-dimensional deformation of the sheet steel necessarily causes stretching of the steel, particularly at those locations which are subjected to the greatest three-dimensional deformation.
  • This stretching can typically be in the range of from 8% to 10%, and the net effect is that the thickness of the sheet steel at the stretched locations can be significantly reduced by this degree.
  • Such significant thickness reduction hence results in areas of the sheet being of significantly reduced strength, and hence these reduced strength areas can dictate and control the design of the overall stamped part, thereby requiring initial use of a sheet thickness greater than would otherwise be required so as to compensate for the thickness reduction caused by stretching.
  • stamping large sheets to define large three- dimensional panels also often results in undesired surface stretch marks or blemishes in the finished product.
  • the stamping operation also typically requires that the sheet be significantly oversized relative to the finished product so as to permit trimming of the sheet around the entire peripheral edge of the finished stamped member, and this hence results in significant waste.
  • a further and significantly disadvantageous factor associated with use of stamped sheet steel panels for vehicle box assemblies is the cost associated with the manufacture of the required stamping tools, and the significant number of such tools required to form the different stamped panels. Since the stamped panels defining the front and side walls of the box assembly, as well as the bed, are all of rather large size, the stamping tool required to form a single panel is necessarily large and complex, and hence extremely costly to manufacture. The complexity associated with such tooling is further increased by the fact that the side and front panels typically have reinforcing channels formed along the upper edges thereof, which channels define either inverted U-shaped configurations or sometimes even a closed hollow channel, whereby the stamping tooling for such shapes involves multiple stamping steps and hence is complex and expensive.
  • stamping tooling The cost of the stamping tooling is further exacerbated by the fact that each stamped part requires its own customized stamping tooling.
  • the front panel, the right side panel and the left side panel of the bed assembly all require their own customized tooling.
  • different tooling must be provided to permit manufacture of the right and left side panels for each different bed length.
  • the overall net effect is that the tooling is not only extremely costly, but the tooling also requires significant floor space in the factory, and additional labor for operation thereof.
  • FIG. 1 Several currently known constructions for vehicle box assemblies employing a significant number of stamped sheet steel panels are illustrated by Figures 1-4.
  • a box assembly 10 as associated with a pickup truck employs right and left upright inner side panels Ii and 12, respectively, joined to an upright front panel 13.
  • the bottom of the box assembly is closed by a generally horizontal bed 14 which, in this conventional construction, employs a multiple-piece construction defined predominantly by a center bed panel
  • each of the front panel, right side panel, left side panel and bed are formed as stamped steel sheet members, all different, and in fact the bed in this example is formed by a plurality (here five) of stamped members.
  • the wheel well covers 18, which are also typically separate stampings, are welded to the respective side panel and to the bed during the assembly process.
  • Figure 2 illustrates another known construction of a box assembly which is virtually identical to the box assembly of Figure 1 described above, except that the bed 14' in Figure 2 is constructed as a one-piece stamped panel having wheel well openings formed in opposite sides thereof, typically by means of a separate stamping operation, thereby eliminating the need for separate side bed panels.
  • the construction of the box assembly of Figure 2 is in all other respects generally similar to that illustrated by Figure 1, and hence possesses generally the same structural and cost disadvantages.
  • FIG 3 there is illustrated improvements with respect to a box assembly for a pickup truck, which improvements are illustrated in greater detail in U.S. Patent No. 6 644 721, owned by the Assignee hereof.
  • the box assembly illustrated in Figure 3 is constructed generally the same as the box assembly shown in Figure 1 except that the center floor pan 15 in Figure 3 is constructed as a one-piece roll- formed member which provides improved performance and weight reduction.
  • FIG 4 depicts another improved construction of the box assembly developed by the Assignee hereof.
  • This improved box construction generally corresponds to the box construction of Figure 2 except that the full- sized bed member 14' is constructed as a roll-formed member, rather than as a stamped member.
  • This roll- formed construction of the one-piece bed member as disclosed in greater detail in Assignee's U.S. Patent No. 6 128 815, has been successfully commercially adopted and is currently in use on models of pickup trucks currently being sold.
  • the side panel, the adjacent wheel well cover and adjacent front and rear side bed panels can be formed as a one-piece stamping, a different such stamping being required for each of the right and left sides of the box assembly.
  • stamping due to its size and complex three-dimensional shape, requires complex and costly tooling.
  • an object of this invention to provide an improved roll-formed component part for a vehicle box assembly, specifically a monolithic one-piece roll-formed panel member which is also transversely bent into an L-shaped longitudinal configuration so as to form both front and bed panels, which component part is believed to provide improved characteristics with respect to construction, assembly and cost efficiencies with respect to materials, assembly and tooling, and which at the same time retains or provides improved performance characteristics with respect to the assembled box assembly.
  • the improved roll-formed component of the present invention is believed to provide the assembled box assembly with improvements with respect to reduction in overall weight, reduction with respect to overall usage of material, reduction with respect to material cost, simplification with respect to required assembly, handling and manipulation, significant reduction with respect to tooling costs, and an ability to utilize the same tooling to facilitate manufacture of multiple or different sized parts.
  • an improved monolithic one-piece roll-formed panel member for a vehicle bed assembly which panel member during roll-forming thereof is provided with alternating grooves and ribs extending lengthwise of the panel member in parallel relationship, which alternating grooves and ribs are disposed sidewardly across a significant width of the panel member.
  • the monolithic flat panel member is thereafter bent transversely thereacross through a generally 90° angle so as to define a first elongate and generally horizontal panel part which functions as a bed for the box assembly, and which is integrally and monolithically joined through the 90° bend to a shorter upright panel section which is of lesser longitudinal extent and which functions as a front side wall for the box assembly.
  • the alternating ribs and grooves as roll-formed in the panel member extend vertically throughout the front side panel part and thence extend through the 90° bend so as to project longitudinally in the lengthwise direction of the bed panel part so as to effectively terminate at the rear edge thereof.
  • the roll-formed panel member may have a width which generally corresponds to the width of the box assembly so that the bed and front panel parts both generally correspond to and occupy the full width of the box assembly.
  • the side portions of the bed panel part may have wheel well openings formed therein, such as by a stamping operation, to permit securement to and cooperation with separate wheel well housings.
  • the side portions of the roll-formed panel member are preferably flat (i.e., free of roll-formed ribs and grooves) so as to leave a flat edge around the wheel well opening to facilitate securement to the wheel well housing.
  • the roll-formed panel member defining the bed and front wall panel parts may have a width which more closely corresponds to the width between the wheel well housings, in which case the box assembly is provided with front and rear bed sections (either separate from or integrally joined to the side wall panel) cooperating with the wheel well housing and the roll-formed bed panel, as well as front panel end extenders which cooperate with the roll- formed front panel so as to permit forming of the vehicle box assembly.
  • an improved box assembly for a vehicle such as a pickup truck
  • box assembly employs a roll-formed bed panel and a roll-formed front panel which is integrally and monolithically joined to the bed panel through an approximately 90° bend section which extends transversely across the panel, and which may additionally employ a roll-formed upright side panel.
  • the roll- forming of large panel members associated with the box assembly permits minimal usage of material in terms of both square footage of material as well as material thickness, thereby minimizing cost and weight of the box assembly, and results in panels of substantially uniform thickness throughout the longitudinal transverse directions thereof.
  • roll-formed panels is also desirable since it permits the panels to be formed from high strength steel if desired, specifically sheet steel having a yield strength in the range of from about 50,000 psi to about 100,000 psi, which high strength steel is typically not feasible for use with large stamped panels.
  • Figure 1 is a top plan view of a conventional pickup truck box assembly which illustrates a first conventional construction of the assembly.
  • Figure 2 is a top plan view similar to Figure 1 but illustrating a second conventional construction of the box assembly.
  • Figure 3 is an exploded view of a box assembly corresponding generally to Figure 1 but illustrating a known variation of the bed assembly.
  • Figure 4 is an exploded perspective view illustrating the box assembly of Figure 2 but illustrating a known variation of the bed assembly.
  • Figure 5 is an exploded fragmentary perspective view showing parts associated with an improved vehicle box assembly constructed in accordance with the present invention.
  • Figure 6 is a fragmentary perspective view showing the parts of Figure 5 in an assembled condition.
  • Figure 7 is an enlarged fragmentary cross- sectional view as taken in the direction of arrow 7 in Figure 6.
  • Figure 8 is an enlarged fragmentary cross- sectional view as taken generally along line 8-8 in Figure 5.
  • Figure 9 is a flow diagram which diagrammatically illustrates the forming process for the roll-formed monolithic panel member which defines both bed and upright front panel portions of the box assembly.
  • Figure 10 is a diagrammatic view which illustrates a bender for transverse bending of the roll- formed flat panel.
  • Figure 11 is an exploded perspective view similar to Figure 5 but illustrating a variation thereof.
  • Figure 12 illustrates an extension on the upright filler panel.
  • Figure 13 illustrates a monolithic one-piece side panel assembly which can be preferably utilized in conjunction with the roll-formed front and floor panel member of Figure 11.
  • Figure 14 illustrates the one-piece side assembly of Figure 13 in assembled relationship with the roll-formed front and floor wall panel member of Figure 11.
  • the box assembly 21 includes a bed or floor pan arrangement 22 which is supported on a plurality of support or cross rails extending transversely thereunder, including a front cross rail 23 disposed adjacent the forward end of the floor, one or more generally parallel intermediate cross rails 24 disposed in rearwardly spaced but generally parallel relationship beneath the floor, and a rear cross rail 25 which supportingly engages the floor beneath the rear edge thereof.
  • An upright front panel 26 projects upwardly from the floor adjacent the front end of the box assembly, and opposed right and left upright side panels 27 project upwardly from opposite sides of the floor and have their forward edges rigidly joined to opposite ends of the front panel 26.
  • Only the right side of the box assembly is illustrated in Figures 5 and 6, the left side being omitted for clarity of illustration, but it will be understood that the left side of the box assembly is typically substantially a mirror image of the right side as shown.
  • the floor 22 and side wall panels 27 are each rigidly joined by a hollow three-dimensional wheel well cover or housing 28 which around the edge thereof is fixedly joined to both the side wall and the floor so as to isolate the rear wheel of the vehicle from the interior of the box assembly.
  • Each upright side wall 27 also has a rear post or upright 29 associated with the rear edge thereof to provide structural reinforcement.
  • the rear post provides a structural connection between the inner side panel 27 and the outer skin of the vehicle, and also provides strength to permit support for a conventional rear tailgate as associated with the box assembly.
  • the bed or floor 22 is preferably constructed as a monolithic one-piece roll- formed member having a series of reinforcing channels or ribs which project upwardly from the sheet and extend lengthwise so as to terminate substantially adjacent the front and rear edges of the bed, with the channels being spaced apart in the sideward or transverse direction of the bed member.
  • the bed member 22 in this embodiment extends the full width of the box assembly so that the side edges of the bed member terminate directly adjacent the side panels 27, and the side edges of the bed member have wheel well openings 31 formed therein to accommodate the rear vehicle wheels.
  • the wheel well openings 31 are enclosed by conventional wheel well covers 28, the latter typically being of a stamped construction.
  • the rear edge of the bed 22 cooperates with the rear cross rail 25 which, in a preferred construction, can be provided with a series of sidewardly spaced upward projections which nestingly cooperate with the channels associated with the bed so as to reinforce the rear bed edge.
  • Use of projections associated with the rear rail for nesting cooperation with the rear edge of the bed is, however, optional .
  • FIG. 8 there is illustrated in greater detail a preferred cross-sectional view through the ribs and valleys which are roll-formed lengthwise of the bed 22.
  • the roll forming preferably creates a plurality of generally parallel and sidewardly spaced channels or ribs 33 which protrude upwardly and extend lengthwise of the bed member, and which are sidewardly spaced apart by intermediate grooves or recesses 34.
  • the channel or rib 33 preferably has a generally flat top wall 36 which, at opposite side edges, is joined to a pair of side walls 37 which flare or taper outwardly and downwardly for joinder to the bottom walls 38 of the adjacent grooves 34.
  • the channels 33 have the top walls 36 thereof provided with a width which is substantially greater than the width of the valley base walls 38. This permits the overall planar support area of the bed, as defined by the total area of the top walls 36, to be of large magnitude to thus facilitate utilization of the vehicle bed since these upper surfaces 36 effectively define the load engaging plane of the bed.
  • the bed 22 includes a side portion 40 which extends inwardly from and along each side edge 43 and which permits forming of the wheel well opening 31 therein.
  • front and rear secondary bed sections 41 and 42 which protrude inwardly from the edge 43 by a transverse width which corresponds to or slightly exceeds the transverse width of the wheel well opening 31.
  • These bed sections 41 and 42 are respectively defined forwardly and rearwardly of the wheel well opening 31.
  • the edge section 40 of the roll-formed bed member, as illustrated in Figure 8, is preferably left in a flat condition, that is, it is not provided with roll-formed ribs therein during the roll forming operation.
  • This flat edge section 40 hence significantly facilitates the forming of the wheel well opening 31 thereon, thereby leaving a generally flat planar edge around the wheel well opening, which also subsequently facilitates the attachment, as by welding, of the wheel well housing 28 to the edge of the wheel well opening 31.
  • the edge portion 40 of the bed member which includes the front and rear portions 41 and 42, is preferably not subject to formation of channels or ribs therein during the roll forming operation, it will be appreciated that these sections can be provided with channels or ribs roll-formed therein if considered necessary or desirable.
  • the upright front panel 26 is also of a roll- formed construction having a series of reinforcing channels or ribs projecting vertically upwardly therealong, the latter effectively being extensions of the channels or ribs 33 associated with the bed 22.
  • the bed 22 and front panel 26 are effectively defined by a monolithic, one-piece panel member 30 which is initially roll formed in a straight condition from flat sheet steel so that the panel member 30 has the reinforcing channels or ribs 33 and intermediate valleys 34 extending lengthwise throughout the longitudinal extent thereof.
  • the roll-formed panel member 30 After the roll-formed panel member 30 has been cut to length (which length corresponds to the longitudinal length of the bed 22 plus the height of the front panel 26) , then the roll-formed panel member 30 is bent perpendicularly across the width thereof to define a generally rounded 90° bend section 45. This thus results in the front panel 26 projecting upwardly in generally perpendicular relationship to the bed 22, but constituting an integral and monolithic upward extension from the front end of the bed through the bend section 45.
  • the resulting front panel 26 hence has the channels 33 extending vertically throughout the height thereof, thereby providing the front panel 26 with significantly improved strength and rigidity in comparison to conventional stamped front panels.
  • the upper edge of roll- formed front panel 26 can have an additional stamping operation formed thereon if desired, subsequent to roll forming of the flat panel member, so as to define a reinforcing flange or channel extending along the upper edge of the front panel 26.
  • a separate member such as a channel member 46 as shown in Figure 7, can be disposed to extend along the upper edge of the front panel 26 and be suitably fixed thereto, such as by welding.
  • side panel 27 illustrated in Figure 5 is also preferably of a roll-formed construction, it will be appreciated that the side panel 27 could be of stamped construction if desired.
  • a steel sheet is normally supplied in the form of a large coil 51 as provided on a coil feed rack 52 which can be positioned adjacent a cradle 53 onto which the coil 52 can be transferred for support during the manufacturing operation.
  • the cradle 53 has conventional structure associated therewith so as to effect straightening of the sheet material as it is discharged therefrom in the form of a substantially continuous metal sheet 54.
  • the sheet material is fed through a combined end shear/welder 56 which trims the leading and trailing ends of each coil and welds the trimmed trailing end of one coil to the leading trimmed end of the next coil so as to permit a substantially continuous sheet 54 to be fed into and through the subsequent manufacturing stations.
  • the continuous steel sheet 54 After passing through the shear/welder 56 the continuous steel sheet 54 progressively moves through a conventional multi-stage roll mill or roll former 57 which progressively reforms the steel sheet 54 so that, while the steel sheet is substantially flat when entering the leading end of the roll mill 57, the steel sheet is suitably deformed so as to have the finished cross section of the bed 22 and front panel 26 (as shown in Figure 8) when leaving the discharge end of the mill 57.
  • the progressive reforming of the steel sheet as it passes through the mill 57 is diagrammatically illustrated by the progressive decreasing width of the steel sheet as it moves longitudinally through the mill.
  • the continuous but deformed steel sheet 58 Upon leaving the roll mill 57, the continuous but deformed steel sheet 58 has the cross section of the bed 22 and panel 26 as illustrated in Figure 8, and if desired can then be fed through a stamping station (not shown) to permit formation of the wheel well openings 31 through the non-deformed side portions 40 of the steel sheet at uniform spaced intervals therealong. Alternatively, the wheel well openings can be stamped or formed in the side portions 40 during a subsequent forming operation, such as after the deformed sheet 58 is cut to length.
  • the continuous deformed steel sheet 58 departing the roll mill 57 is fed into and through a cutoff press 59 which cuts the deformed steel sheet 58 at desired spaced distances corresponding to the length of the bed 22 combined with the height of the front panel 26.
  • the individually cut roll-formed panels 30' while still in a generally flat condition, are discharged from the cutoff press 59 and can be moved away from the press in a conventional manner, such as by a conveyor 61.
  • the flat roll-formed panel 30' can then be moved to a subsequent processing station, such as indicated at 62, which effects transverse bending of roll-formed flat panel 30' generally along the line 45' to hence effect creation of the L-shaped panel member 30 which thus defines the bed and panel sections 22 and 26 respectively joined through the integral and monolithic bent section 45 as illustrated in Figure 5.
  • the non-rolled side sections 40 of the panel extends through the bend section 45 and project upwardly so as to define end portions of the front wall panel 26, which end portions are free of ribs or channels consistent with the flat wall defined by the bed sections 41 and 42.
  • such bending device 62 may assume many different configurations but will preferably involve features similar to a conventional bender of the type known as a "wing" type bender.
  • a bending device as indicated at 62 in Figure 9
  • Such is only diagrammatically illustrated in Figure 10 and includes a stationary bottom support or die 71, the upper surface 72 having a generally channelled or corrugated profile corresponding to that of the roll-formed flat panel 30' .
  • the flat panel 30' will be supported on the main support 71 so that a desired length thereof will project over a moveable bending tool 73, the latter typically having a flat upper surface so that it engages only the lower or flat bottom walls associated with the valleys of the panel member 30' .
  • a top die or support 74 is disposed directly over the stationary support 71 and defines thereon a small radius (i.e. about two to three inch radius) rounded corner 77 which joins bottom surface 76 to an upwardly projecting surface 75.
  • the pressing member 73 which engages solely the flat bottom surfaces of the valleys defined on the panel member 30' is moved upwardly, thereby causing the cantilevered portion 30" of panel member 30' to be bent upwardly around the corner 77 into a generally upright position so that the extension 30" hence is effectively moved into nesting engagement with the profiled upright surface 75.
  • the moveable pressing member 73 may be moved vertically upwardly so as to progressively reshape the panel extension 30" about the curved corner die 77, or alternatively the pressing member 73 may be pivotally swung upwardly about an axis which is approximately aligned with the center of the curved corner 77 so as to engage the extension 30" over a longer extent to hence effect upward swinging and hence bending about the curved corner 77. Bending of this general type is known to those of ordinary skill in this technology, and further detailed description thereof is believed unnecessary.
  • FIG. 11 As an alternate and preferred construction for the present invention, and referring to Figure 11, there is illustrated a modified monolithic one-piece roll- formed panel 3OA which is identical to the panel 30 described above except that panel 3OA has a width which is designed to extend across only the main center load- bearing region of the box assembly, namely a width which approximately corresponds to the width between the wheel well housings 28.
  • This narrower roll-formed panel member 3OA hence has the sidewardly alternating stiffening ribs 33 and valleys 34 (as shown in Figure 8) disposed in sideward but parallel relationship across substantially the entire width thereof.
  • the L-shaped panel 3OA cooperates with side panels and wheel well housings in generally the same manner as described above, except that in this situation there is additionally provided bed filler panel sections 49 which are disposed on opposite sides of the roll-formed bed panel 22A and extend along the upright side panels 27 so as to occupy the regions both rearwardly and forwardly of the wheel well covers 28. There is also provided front upright filler panels 48 which join to opposite upright edges of the roll- formed front panel 26A and extend outwardly for joinder to the respective inner side wall 27. These filler panels 48 hence cooperate with the front panel 26A so as to define the full-width front wall of the box assembly.
  • the bed panel section 22A and bed filler panels 49 are typically provided with down-turned edge flanges, such as indicated at 66 in Figure 11, to permit the panels to be welded together.
  • Front panels 26A and 49 can be similarly joined using flanges, or alternately can be provided with overlapping edge parts which can be welded together, as shown in Figure 12.
  • the front filler panel 48 is preferably provided with an outward extension 48A which extends beyond the inner side panel 27 so as to be joined to the outer side (i.e. quarter) panel (not shown) in a conventional manner.
  • the inner side wall 27, wheel well cover 28 and associated bed and front filler panel sections 49 and 48 can be individual stamped pieces, but preferably are defined by a monolithic one-piece stamped assembly 70 (as shown in Figures 13 and 14) , namely one-piece right and left assemblies stamped from thin sheet steel.
  • a monolithic one-piece stamped assembly 70 as shown in Figures 13 and 14
  • the width of the flat steel sheet, as provided in the coil will substantially correspond to the width of the finished panel if flattened out into a planar condition, whereby trimming of the sheet or of the finished panel is generally unnecessary, and minimal usage of sheet material is achieved.
  • the roll- forming of the critical panels effectively eliminates or at least greatly minimizes stretching (i.e., thickness reduction) of the sheet during shaping of the panel, whereby a steel sheet of reduced thickness can hence be initially utilized to permit forming of the panel, particularly in comparison to stamped panels, and the resulting roll-formed panels are substantially of uniform thickness throughout.
  • This hence minimizes the finished weight of the panel, reduces material costs, and greatly simplifies required tooling which significantly reduces tooling costs, and at the same time provides tooling having a significantly greater degree of flexibility.
  • the design of roll-formers involves the application of conventional techniques known to those of ordinary skill in the roll-forming art, whereby further description and explanation of the roll-former is believed unnecessary.
  • the roll-forming of the principal panels such as the side and front wall panels as well as the floor panels associated with the box assembly, as described above, is also advantageous inasmuch as this enables the panels to be more readily formed using high strength steel sheets, particularly thin steel sheets having a yield strength in the range of from about 50,000 psi to about 100,000 psi.
  • High strength steel sheets can be more readily shaped and deformed by roll-forming so as to provide panels having the desired three-dimensional contour, specifically permitting use of deeper draws or formations than is typical with stamping, thereby additionally providing design opportunity to utilize thinner materials and provide greater weight reduction while also providing more severe (i.e. deeper) three- dimensional shapes.
  • roll-formed panels for use in a truck box can be and typically are provided with various attachment flanges.
  • flanges are typically provided on the edge of either the front panel or the side panel for permitting securement at the front corners of the box assembly, and are also provided around the wheel well opening when a separate wheel well housing is utilized.
  • Such flanges can be formed, trimmed and shaped as desired utilizing conventional pressing and shaping dies, whereby further detailed description relative to such flanges is believed unnecessary.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
  • Body Structure For Vehicles (AREA)

Abstract

L'invention concerne un ensemble carrosserie autoporteuse de véhicule (21) amélioré qui comporte une pièce de panneau avant (26) verticale et une pièce de panneau de plancher (22) horizontale définies par un élément de feuille de tôle laminé en une seule pièce monolithique et présentant la configuration tridimensionnelle souhaitée. L'élément de feuille de tôle est laminé dans le sens de sa longueur pour créer une pluralité de nervures de renforcement (33) parallèles. L'élément laminé est ensuite plié transversalement pour définir les deux pièces de panneau avant et de panneau de plancher.
PCT/US2006/001616 2006-01-17 2006-01-17 Panneau avant et soubassement formés d'une seule pièce par laminage pour ensemble carrosserie autoporteuse de véhicule WO2007084120A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/US2006/001616 WO2007084120A1 (fr) 2006-01-17 2006-01-17 Panneau avant et soubassement formés d'une seule pièce par laminage pour ensemble carrosserie autoporteuse de véhicule

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2006/001616 WO2007084120A1 (fr) 2006-01-17 2006-01-17 Panneau avant et soubassement formés d'une seule pièce par laminage pour ensemble carrosserie autoporteuse de véhicule

Publications (1)

Publication Number Publication Date
WO2007084120A1 true WO2007084120A1 (fr) 2007-07-26

Family

ID=36847840

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2006/001616 WO2007084120A1 (fr) 2006-01-17 2006-01-17 Panneau avant et soubassement formés d'une seule pièce par laminage pour ensemble carrosserie autoporteuse de véhicule

Country Status (1)

Country Link
WO (1) WO2007084120A1 (fr)

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6128815A (en) * 1997-01-10 2000-10-10 Pullman Industries, Inc. Process of forming a vehicle bed
US20050241152A1 (en) * 2004-04-13 2005-11-03 Mcnulty Frank G Manufacturing process for roll-formed vehicle panels

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6128815A (en) * 1997-01-10 2000-10-10 Pullman Industries, Inc. Process of forming a vehicle bed
US20050241152A1 (en) * 2004-04-13 2005-11-03 Mcnulty Frank G Manufacturing process for roll-formed vehicle panels

Similar Documents

Publication Publication Date Title
US7290827B2 (en) Integrated roll-formed front and bed panel for vehicle box assembly
US7275784B2 (en) Two-piece side and floor panel arrangement for box assembly
US7284787B2 (en) Roll-formed panels for vehicle box assembly
US7703208B2 (en) Manufacturing process for roll-formed vehicle panels
US6170905B1 (en) Truck bed and method of manufacture
JP3310979B2 (ja) 車両ベッド及びその製造方法
US6128815A (en) Process of forming a vehicle bed
US5938272A (en) Vehicle bed
US6799792B2 (en) Vehicle bed edge and manufacturing process
US6347454B1 (en) Vehicle bed edge manufacturing process
US7192071B2 (en) Bulkhead for raising strength and rigidity of vehicular frame members
US7152911B1 (en) Vehicle bed and cross rail attachment
US7731271B2 (en) Vehicle bed edge construction and manufacturing process therefor
JPH1067344A (ja) 自動車、特に乗用車のアンダーボデー
WO2006112904A1 (fr) Panneau en deux parties (ridelle +partie de plancher) pour caisson de vehicule
US6026573A (en) Method for manufacturing a side rail for a vehicle frame assembly
WO2007084120A1 (fr) Panneau avant et soubassement formés d'une seule pièce par laminage pour ensemble carrosserie autoporteuse de véhicule
CN101193789A (zh) 用于车厢组件的两件式侧板及地板构造形式
CA2464233A1 (fr) Caisse de vehicule avec panneaux lamines
MXPA99006467A (en) Vehicle bed

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application
NENP Non-entry into the national phase

Ref country code: DE

32PN Ep: public notification in the ep bulletin as address of the adressee cannot be established

Free format text: NOTING OF LOSS OF RIGHTS PURSUANT TO RULE 112(1) EPC

122 Ep: pct application non-entry in european phase

Ref document number: 06718660

Country of ref document: EP

Kind code of ref document: A1