US5729463A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Designing and producing lightweight automobile bodies
Assignee: ULSAB Trust
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Filing: 1995-09-01
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Granted: 1998-03-17
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Expires: 2015-09-01
Abstract
Abstract Method and system for designing and producing a lightweight automobile or vehicle body. Structural performance targets are selected, a beam model analysis is conducted, and a body-in-white design is developed. A shell model is created and analyzed and material gauges and manufacturing processes for the body components are selected. A structural analysis is conducted to determine whether the shell model meets the selected structural performance targets. A crash model is created, analyzed, and modified until satisfactory crash requirements are met. A final structural analysis is conducted to determine whether the shell model meets the selected structural performance targets.
Inventors
- 👤 Gerhard Koenig
- 👤 Robert Koehr
- 👤 Felix Kybart
- 👤 Sigfried Walter
- 👤 John Catterall
- 👤 John Krumbach
- 👤 Rolf Heyll
- 👤 Andrew Wolf
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-30 23:51
CPC Classifications
G; G06; G06F; G06F30/00; G06F30/10; G06F30/15; B; B23; B23K; B23K11/00; B23K11/10; B23K11/11; B23K26/00; B23K26/20; B23K26/21; B23K26/22; B62; B62D; B62D65/00; B23K2101/00; B23K2101/006; B23K2101/18; B23K2101/185
Claims Analysis
Total Claims: 33
Claim 1
Independent Claim
133 words
A process for producing a light-weight vehicle body comprising a plurality of components, said process comprising the steps of: a. selecting at least one type of material for said components; b. selecting structural performance targets; c. conducting a beam model analysis; d. designing a body-in-white; e. creating a shell model; f. selecting material gauges for said components; g. selecting manufacturing processes for said components; h. conducting a first structural analysis; i. determining whether said shell model meets said selected structural performance targets; j. selecting crash requirements; k. creating a crash model; l. conducting a crash model analysis; m. determining whether said crash model meets said selected crash requirements; n. conducting a second structural analysis; and o. determining for at least a second time whether said shell model meets said selected structural performance targets.
Claim 2
Dependent Claim
133 words
A process for producing a light-weight vehicle body comprising a plurality of components, said process comprising the steps of: a. selecting at least one type of material for said components; b. selecting structural performance targets; c. conducting a beam model analysis; d. designing a body-in-white; e. creating a shell model; f. selecting material gauges for said components; g. selecting manufacturing processes for said components; h. conducting a first structural analysis; i. determining whether said shell model meets said selected structural performance targets; j. selecting crash requirements; k. creating a crash model; l. conducting a crash model analysis; m. determining whether said crash model meets said selected crash requirements; n. conducting a second structural analysis; and o. determining for at least a second time whether said shell model meets said selected structural performance targets.
Claim 3
Dependent Claim
17 words
The process in accordance with claim 1 wherein said material for said components comprises a steel material.
Claim 4
Dependent Claim
28 words
The process in accordance with claim 2 wherein mild steel is used for at least one component and high-strength steel is used for at least one other component.
Claim 5
Dependent Claim
36 words
The process in accordance with claim 1 wherein said material comprises a steel material and said manufacturing processes for said components are selected from the group comprising roll forming, hot forming, tailor blanking, hydro-forming and stamping.
Claim 6
Dependent Claim
19 words
The process in accordance with claim 1 wherein said shell model is created utilizing data from various load tests.
Claim 7
Dependent Claim
36 words
The process in accordance with claim 1 wherein said crash model analysis comprises conducting computer simulated crash tests selected from the group comprising front crash test, rear crash test, roof crush test and side impact test.
Claim 8
Dependent Claim
20 words
The process in accordance with claim 6 wherein said crash test group further comprises at least one off-center crash test.
Claim 9
Dependent Claim
24 words
The process in accordance with claim 1 wherein said vehicle body is produced from a combination of unibody and hydroform intensive body design styles.
Claim 10
Dependent Claim
20 words
The process in accordance with claim 1 wherein said material for a plurality of said components comprises an aluminum material.
Claim 11
Dependent Claim
20 words
The process in accordance with claim 1 wherein said material for a plurality of said components comprises a synthetic material.
Claim 12
Dependent Claim
15 words
The process in accordance with claim 10 wherein said synthetic material comprises a plastic material.
Claim 13
Dependent Claim
20 words
The process in accordance with claim 1 wherein said material for a plurality of said components comprises a composite material.
Claim 14
Dependent Claim
35 words
The process in accordance with claim 1 wherein said material for a first plurality of said components comprises a steel material and said material for a second plurality of said components comprises a laminate material.
Claim 15
Dependent Claim
21 words
The process in accordance with claim 13 wherein said laminate material comprises a plastic core positioned between thin metal panel members.
Claim 16
Dependent Claim
37 words
The process in accordance with claim 13 wherein said second plurality of said components comprises at least one component selected from the group comprising a dash panel member, a floor panel member, and a wheel tub member.
Claim 17
Dependent Claim
18 words
The process in accordance with claim 1 wherein at least one component is made from a laminate material.
Claim 18
Dependent Claim
34 words
The process in accordance with claim 1 wherein: a. a first plurality of components is made from a stamped steel material; b. a second plurality of components is made from a hydroformed steel material.
Claim 19
Dependent Claim
23 words
The process in accordance with claim 17 wherein at least one of said stamped steel components is made by a tailor blanking process.
Claim 20
Dependent Claim
23 words
The process in accordance with claim 17 wherein at least one of said stamped steel components is made by a hot forming process.
Claim 21
Dependent Claim
19 words
The process in accordance with claim 17 further comprising a third plurality of components made from a laminated material.
Claim 22
Dependent Claim
20 words
The process in accordance with claim 17 further comprising at least one component made from a roll formed steel material.
Claim 23
Dependent Claim
31 words
The process in accordance with claim 1 wherein said selected structural performance targets comprise a prespecified static torsion, a prespecified static bending, a prespecified mass, and a prespecified mode of vibration.
Claim 24
Dependent Claim
14 words
The process in accordance with claim 22 wherein said prespecified mass is 200 kg.
Claim 25
Dependent Claim
18 words
The process in accordance with claim 22 wherein said prespecified mode of vibration is at least 40 Hz.
Claim 26
Dependent Claim
25 words
The process in accordance with claim 1 further comprising the step of revising and modifying said shell model in accordance with said first structural analysis.
Claim 27
Dependent Claim
25 words
The process in accordance with claim 1 further comprising the step of revising and modifying said crash model in accordance with said crash model analysis.
Claim 28
Dependent Claim
28 words
The process in accordance with claim 1 further comprising the step of revising and modifying said second determination whether said shell model meets said selected structural performance targets.
Claim 29
Dependent Claim
24 words
The process in accordance with claim 1 wherein said beam model analysis and said shell model analysis are conducted using computer finite element software.
Claim 30
Dependent Claim
18 words
The process in accordance with claim 1 wherein said crash model analysis is conducted using computer simulation software.
Claim 31
Dependent Claim
17 words
The process in accordance with claim 29 wherein a supercomputer is utilized to conduct said computer simulation.
Claim 32
Dependent Claim
214 words
A process for producing a lightweight body-in-white comprised of a plurality of components, the plurality of components being made of a steel material, said process comprising the steps of: a. selecting structural performance targets for the body-in-white; b. conducting a finite element beam model analysis to determine the locations and cross-sections of said components; c. designing a preliminary body-in-white; d. creating a finite element shell model; e. selecting the thickness of the material for said components, as well as the manufacturing processes used to produce said components, said shell model having at least a first component made from stamped steel material, at least a second component made from hydroformed steel material, and at least a third component made from a tailor blanked material; f. conducting a first structural analysis to determine whether said shell model meets said selected structural performance targets; g. modifying said shell model where necessary in accordance with said first structural analysis; h. selecting crash requirements for said body-in-white; i. creating a finite element crash model; j. conducting a computer simulated crash model analysis to determine whether said crash model meets said selected crash requirements; and k. conducting a second structural analysis and modifying said shell model where necessary in accordance with said crash model analysis and said second structural analysis.
Claim 33
Dependent Claim
214 words
A process for producing a lightweight body-in-white comprised of a plurality of components, the plurality of components being made of a steel material, said process comprising the steps of: a. selecting structural performance targets for the body-in-white; b. conducting a finite element beam model analysis to determine the locations and cross-sections of said components; c. designing a preliminary body-in-white; d. creating a finite element shell model; e. selecting the thickness of the material for said components, as well as the manufacturing processes used to produce said components, said shell model having at least a first component made from stamped steel material, at least a second component made from hydroformed steel material, and at least a third component made from a tailor blanked material; f. conducting a first structural analysis to determine whether said shell model meets said selected structural performance targets; g. modifying said shell model where necessary in accordance with said first structural analysis; h. selecting crash requirements for said body-in-white; i. creating a finite element crash model; j. conducting a computer simulated crash model analysis to determine whether said crash model meets said selected crash requirements; and k. conducting a second structural analysis and modifying said shell model where necessary in accordance with said crash model analysis and said second structural analysis.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2001-03-16 | 2001-09-15 | 2002-03-17 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2005-03-16 | 2005-09-15 | 2006-03-17 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2009-03-16 | 2009-09-15 | 2010-03-17 | $7700.00 | Window Closed / Lapsed |