Unitary rear rail structure for a vehicle and methods

A method for manufacturing a unitary rear rail structure for a vehicle framework, the method comprising:

• providing a first blank and a second blank,
• arranging the first and second blanks such that the first blank partially overlaps the second blank in an overlapping region;
• joining the first blank to the second blank at the overlapping region to form a combined blank;
• heating the combined blank at least partially to above an austenization temperature;
• and
• press hardening the heated combined blank to form the unitary rear rail structure, wherein,
• the formed unitary rear rail structure comprises a first and a second rear rail portion and one or more cross-member portions, and wherein
• the overlapping region substantially corresponds to a transition between the first rail portion and one of the cross-member portions, and wherein
• wherein the overlapping region extends over an entire width of the cross-member and at least 20 mm into the rail portions.

A method for manufacturing a unitary rear rail structure for a vehicle framework, the method comprising:

• providing a first blank and a second blank,
• arranging the first and second blanks such that the first blank partially overlaps the second blank in an overlapping region;
• joining the first blank to the second blank at the overlapping region to form a combined blank;
• heating the combined blank at least partially to above an austenization temperature;
• and
• press hardening the heated combined blank to form the unitary rear rail structure, wherein,
• the formed unitary rear rail structure comprises a first and a second rear rail portion and one or more cross-member portions, and wherein
• the overlapping region substantially corresponds to a transition between the first rail portion and one of the cross-member portions, and wherein an area of the overlapping region is 20-600 cm2.

A method for manufacturing a unitary rear rail structure for a vehicle framework, the method comprising:

• providing a first blank and a second blank,
• arranging the first and second blanks such that the first blank partially overlaps the second blank in an overlapping region;
• joining the first blank to the second blank at the overlapping region to form a combined blank;
• heating the combined blank at least partially to above an austenization temperature;
• and
• press hardening the heated combined blank to form the unitary rear rail structure, wherein,
• the formed unitary rear rail structure comprises a first and a second rear rail portion and one or more cross-member portions, and wherein
• the overlapping region substantially corresponds to a transition between the first rail portion and one of the cross-member portions, and wherein
• the first rail portion has a U-shaped cross-section, and
• wherein the overlapping region is located at a bottom wall of the U-shaped cross-section.