Structural component and a method of manufacturing such a component

Patent metadata

Field	Value
Publication number	US-9487244-B2
Application number	US-201514819748-A
Country	US
Kind code	B2
Filing date	Aug 6, 2015
Priority date	Aug 15, 2014
Publication date	Nov 8, 2016
Grant date	Nov 8, 2016

Abstract

A structural component for a motor vehicle comprises first and second profiled sheet metal parts joined together by welding spots, which sheet metal parts have opposing free ends arranged to be mating to form an overlapping portion over a predetermined distance. A cross-section of the component through the overlapping portion has a hat shape that comprises first and second edge portions extending in the longitudinal direction of the component, first and second side portions arranged to join a respective edge portion, and a central portion arranged to join the side portions. The free end of the central portion of each sheet metal part comprises at least two tabs separated by a recess, and the tabs of the first and second sheet metal parts are joined to a part of an adjacent central portion by welding. The disclosure further relates to a method for making the component.

First claim

What is claimed is:

1. A structural component for a motor vehicle, the structural component comprising:
first and second profiled sheet metal parts joined together by welding spots, which sheet metal parts have opposing free ends arranged to mate to form an overlapping portion over a predetermined distance, wherein a cross-section of the component through the overlapping portion has a hat shape with each sheet metal part comprising:
first and second edge portions extending in a longitudinal direction of the component;
first and second side portions that are each arranged to join a respective edge portion; and
a central portion arranged to join the side portions;

wherein the free end of the central portion of each sheet metal part comprises at least two tabs separated by a recess, and the tabs of each sheet metal part are joined to a part of an adjacent central portion by welding.

2. The structural component according to claim 1 wherein each recess extends from the free end of a respective central portion past a welding spot on an adjacent tab.

3. The structural component according to claim 1 wherein at least one welding spot is located on each tab adjacent a recess.

4. The structural component according to claim 1 wherein at least one welding spot is located on each of the first and second edge portions.

5. The structural component according to claim 1 wherein at least one welding spot is located on each of the first and second side portions adjacent a respective edge portion.

6. The structural component according to claim 1 wherein the central portions of the first and second sheet metal parts are separated a predetermined distance in the overlapping portion.

7. The structural component according to claim 1 wherein each tab is arranged to be resiliently deformed into contact with an adjacent central portion in the overlapping portion.

8. The structural component according to claim 1 wherein at least one adjoining section of the side portions is provided with a longitudinal relief zone in the overlapping portion, which zone extends a predetermined distance from a respective central portion towards a respective edge portion.

9. The structural component according to claim 1 wherein the first and second profiled sheet metal parts are joined together by spot welds.

10. The structural component according to claim 1 wherein the first and second profiled sheet metal parts are joined together by pulsed laser welds.

11. A method for assembling a structural component for a motor vehicle, the component comprising first and second profiled sheet metal parts, which sheet metal parts have opposing free ends arranged to mate to form an overlapping portion over a predetermined distance, wherein a cross-section of the component through the overlapping portion has a hat shape with each profiled sheet metal part including first and second edge portions extending in a longitudinal direction of the component, first and second side portions that are each arranged to join a respective edge portion, and a central portion arranged to join the side portions, the method comprising:
locating the first and second profiled sheet metal parts in an overlapping position;
clamping the first and second profiled sheet metal parts together along the edge portions;
applying clamping forces to at least two tabs separated by a recess at the free end of each central portion to deform each tab into contact with an adjacent central portion; and
joining the first and second profiled sheet metal parts by welding spots at the first and second edge portions, the first and second side portions and at each tab on the central portion of each profiled sheet metal part.

12. The method according to claim 11 further comprising locating the welding spots on the tabs so that each recess extends from the free end of a respective central portion past a welding spot on an adjacent tab.

13. A structural component for a motor vehicle, the structural component comprising:
first and second profiled sheet metal parts joined together by welding spots, which sheet metal parts have opposing free ends mated to form an overlapping portion, wherein a cross-section of the component through the overlapping portion has a hat shape with each sheet metal part comprising:
first and second edge portions extending in a longitudinal direction of the structural component;
first and second side portions that are each joined to a respective edge portion; and
a central portion joined to the side portions;

wherein the free end of the central portion of each sheet metal part comprises two tabs separated by a recess, and the tabs of each sheet metal part are joined to a part of an adjacent central portion by welding spots.

14. The structural component according to claim 13 wherein each recess extends from the free end of a respective central portion past a welding spot on each tab of the respective central portion.

15. The structural component according to claim 13 wherein at least one welding spot is located on each tab such that the central portions are joined together by at least four welding spots.

16. The structural component according to claim 13 wherein two welding spots are located on each of the first and second edge portions of each of the sheet metal parts.

17. The structural component according to claim 16 wherein, for each edge portion, the welding spots are separated in the longitudinal direction of the structural component.

18. The structural component according to claim 13 wherein two welding spots are located on each of the first and second side portions of each of the sheet metal parts.

19. The structural component according to claim 18 wherein, for each side portion, the welding spots are separated in the longitudinal direction of the structural component.

20. The structural component according to claim 13 wherein each tab is deformed into contact with an adjacent central portion in the overlapping portion.

Assignees

• Volvo Car Corp

Inventors

• Elfwing Jens
• Gustavsson Martin

Classifications

• B23K11/11 Primary

  Spot welding · CPC title

• B60B25/02

  Segmented rims, e.g. with segments arranged in sections; Connecting equipment, e.g. hinges; Insertable flange rings therefor · CPC title

• B23K26/0622

  by shaping pulses · CPC title

• B62D65/02

  Joining sub-units or components to, or positioning sub-units or components with respect to, body shell or other sub-units or components · CPC title

• B60B2360/141

  Sheet-metals · CPC title