# US 11,999,413 B2 · Method for manufacturing a motor vehicle structural component from an extruded multichamber hollow profile

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 11,999,413 B2
- Document ID: US11999413B2
- Status: Granted
- Kind: B2
- Application number: 17/539,239
- Filed: 2021-12-01
- Published: 2023-06-01
- Granted: 2024-06-04
- Earliest claimed: 2021-12-01
- Assignees: Benteler Automobiltechnik GmbH
- Applicants: Benteler Automobiltechnik GmbH
- Inventors: Gaurav Ahuja; Vijay Michael; Per Ivar Stemnes; Jochem Grewe
- Web page: https://patentgrep.com/patent/US11999413B2

## CPC

- B21D 22/025: {for tubular articles}
- B62D 29/008: {predominantly of light alloys, e.g. extruded}
- B21C 23/085: {Making tubes (B21C23/10 take precedence)}
- B21C 23/12: Extruding bent tubes or rods
- B21C 23/142: {Making profiles}
- B21C 35/023: {Work treatment directly following extrusion, e.g. further deformation or surface treatment (B21C35/03 takes precedence; gas treatment B21C23/009)}
- B21D 53/88: other parts for vehicles, e.g. cowlings, mudguards
- B21D 41/02: Enlarging
- B21D: WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL (working or processing of wire B21F)
- B62D: MOTOR VEHICLES; TRAILERS (steering, or guiding on a desired track, of agricultural machines or implements A01B69/00; wheels, castors, axles, increasing wheel adhesion B60B; vehicle tyres, tyre inflation or tyre changing B60C; connections between vehicles of a train or the like B60D; vehicles for use on rail and road, amphibious or convertible vehicles B60F; suspension arrangements B60G; heating, cooling, ventilating or other air treating devices B60H; windows, windscreens, non-fixed roofs, doors or similar devices, protective coverings for vehicles not in use B60J; propulsion plant arrangements, auxiliary drives, transmissions, controls, instrumentation or dashboards B60K; electric equipment or propulsion of electrically-propelled vehicles B60L; power supply for electrically-propelled vehicles B60M; passenger accommodation not otherwise provided for B60N; adaptations for load transportation or to carry special loads or objects B60P; arrangement of signalling or lighting devices, the mounting or supporting thereof or circuits therefor, for vehicles in general B60Q; vehicles, vehicle fittings or vehicle parts not otherwise provided for B60R; servicing, cleaning, repairing, supporting, lifting, or manoeuvring, not otherwise provided for, B60S; brake arrangements, brake control systems or parts thereof B60T; air-cushion vehicles B60V; motor-cycles, accessories therefor B62J, B62K; testing of vehicles G01M)
- B21C: MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES, PROFILES OR LIKE SEMI-MANUFACTURED PRODUCTS OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL

## Abstract

The invention concerns a method for manufacturing a motor vehicle structural component (1) from an extruded multichamber hollow profile, with the following steps: a) provision of an extruded profile (2) with at least two precursor hollow chambers (8, 9) which are separated from one another by an inner wall (7), wherein at least one outer wall (3, 4) of at least one precursor hollow chamber (8, 9), in cross-section perpendicularly to the longitudinal extent of the extruded profile (2), has a region (16) with non-linear course, b) forming of the extruded profile (2) in at least one of its end regions into the motor vehicle structural component (1), wherein at least the region (16) with non-linear course of the at least one outer wall (3, 4) of the at least one precursor hollow chamber (8, 9), with non-linear course in cross-section, is at least partially straightened, with a change in cross-section of the respective precursor hollow chamber (8, 9) into the cross-section of the corresponding hollow chamber (14, 15) of the motor vehicle structural component (1).

## Claims

### Claim 1

A method for manufacturing a motor vehicle structural component from an extruded multichamber hollow profile, with the following steps:
a) provision of an extruded profile with at least two precursor hollow chambers which are separated from one another by an inner wall, wherein at least one outer wall of at least one precursor hollow chamber, in cross-section perpendicularly to a longitudinal extent of the extruded profile, has a region with non-linear course,
b) forming of the extruded profile over an entire longitudinal extent of the extruded profile into the motor vehicle structural component, wherein at least the region with non-linear course of the at least one outer wall of the at least one precursor hollow chamber, with non-linear course in cross-section, is at least partially straightened, with a change in cross-section of the respective precursor hollow chamber into the cross-section of the corresponding hollow chamber of the motor vehicle structural component, and wherein the inner wall remains unchanged during the forming of the extruded profile,
wherein at least on an outer wall of at least one precursor hollow chamber, a non-linear web is arranged which is at least partially straightened in step b).

### Claim 2 (depends on 1)

The method as claimed in claim 1, wherein the forming in step b) takes place in a cavity of a split pressing tool, wherein in one precursor hollow chamber of the extruded profile, the cross-section remains substantially unchanged, and a forming tool or mandrel is inserted, an outer contour of which corresponds to an inner contour of the hollow chamber of the motor vehicle structural component, while in the precursor hollow chamber of the extruded profile of which the cross-section is changed, an expanding forming tool or transversely movable mandrel is inserted which expands or is moved transversely during and/or after closing of the split pressing tool until a definitive form of the hollow chamber of the motor vehicle structural component is achieved.

### Claim 3 (depends on 2)

The method as claimed in claim 2, wherein both a compression and an expansion are carried out inside the split pressing tool in a same pressing stroke.

### Claim 4 (depends on 1)

The method as claimed in claim 1, wherein during the forming in step b), a thickness of at least one outer wall of the hollow chamber with cross-section to be changed is reduced, and a thickness of at least one other outer wall of the hollow chamber with cross-section to be changed remains substantially unchanged.

### Claim 5 (depends on 1)

The method as claimed in claim 1, wherein the forming according to step b) takes place such that a circumscribing circle of the extruded profile has a smaller diameter than a circumscribing circle of the motor vehicle structural component.

### Claim 6 (depends on 1)

The method as claimed in claim 1, wherein the at least one precursor hollow chamber is formed in multiple phases such that firstly a compression takes place of at least one outer wall in a compression direction, and during this a width or a height of the precursor hollow chamber is reduced, and then an expansion takes place of this at least one outer wall in an expansion direction, wherein the expansion direction stands at an angle between 30° and 150° to the compression direction.

### Claim 7 (depends on 1)

The method as claimed claim 1, wherein the at least one precursor hollow chamber is formed in multiple phases such that firstly an expansion of at least one outer wall takes place in an expansion direction, wherein the expansion direction stands at an angle between 30° and 150° to a compression direction, and then a compression of this at least one outer wall takes place in the compression direction and during this a width or a height of the precursor hollow chamber is reduced.

### Claim 8 (depends on 1)

The method as claimed in claim 1, wherein at least one of the hollow chambers of the motor vehicle structural component has a smaller width than the corresponding precursor hollow chamber of the extruded profile.

### Claim 9 (depends on 1)

The method as claimed in claim 1, wherein at least one of the hollow chambers of the motor vehicle structural component has a greater width than the corresponding precursor hollow chamber of the extruded profile.

### Claim 10 (depends on 1)

The method as claimed in claim 1, wherein at least one of the hollow chambers of the motor vehicle structural component has a smaller height than the corresponding precursor hollow chamber of the extruded profile.

### Claim 11 (depends on 1)

The method as claimed in claim 1, wherein at least one of the hollow chambers of the motor vehicle structural component has a greater height than the corresponding precursor hollow chamber of the extruded profile.

### Claim 12 (depends on 1)

The method as claimed in claim 1, wherein the at least one precursor hollow chamber of the extruded profile in cross-section is formed round, oval or arcuate in at least a partial periphery, and is formed into a polygonal hollow chamber of the motor vehicle structural component.