Laser welded structural fender inner blank for mass optimization

Abstract

An inner fender panel for a structural fender of an automotive vehicle is disclosed. The panel includes an outer surface configured for attachment to the inner surface of an outer panel of the fender and an inner surface; the inner panel comprising a plurality of abutting inner fender panel sections that are joined to one another, each inner fender panel section having a thickness, at least two abutting inner fender panel sections having thicknesses that are different. A structural fender for an automotive vehicle is also disclosed. The fender includes a formed outer panel having a viewable outer surface and an inner surface. The fender also includes a formed inner fender panel as described comprising a plurality of abutting inner fender panel sections that are joined to one another, each inner fender panel section having a thickness, at least two abutting inner fender panel sections having thicknesses that are different.

What is claimed is: 
     
         1 . An inner fender panel for a structural fender of an automotive vehicle comprising an outer surface configured for attachment to the inner surface of an outer panel of the structural fender, and an inner surface; the inner fender panel comprising a plurality of abutting inner fender panel sections that are joined to one another, each inner fender panel section having a thickness, at least two abutting inner fender panel sections having thicknesses that are different. 
     
     
         2 . The inner fender panel for a structural fender of  claim 1 , wherein the outer surface is substantially planar. 
     
     
         3 . The inner fender panel for a structural fender of  claim 1 , wherein the outer surfaces of abutting inner fender panel sections having thicknesses that are different are substantially co-planar. 
     
     
         4 . The inner fender panel for a structural fender of  claim 1 , wherein each of the plurality of abutting inner fender panel sections comprise a metal sheet material having a material composition. 
     
     
         5 . The inner fender panel for a structural fender of  claim 4 , wherein the metal sheet material of each of the plurality of abutting inner fender panel sections have the same material composition. 
     
     
         6 . The inner fender panel for a structural fender of  claim 4 , wherein the metal sheet material of the plurality of abutting inner fender panel sections have different material compositions. 
     
     
         7 . The inner fender panel for a structural fender of  claim 4 , wherein the material composition of the metal sheet comprises a steel alloy or an aluminum alloy. 
     
     
         8 . The inner fender panel for a structural fender of  claim 1 , wherein the thickness of the inner fender panel sections range from about 0.75 mm to about 2.5 mm. 
     
     
         9 . The inner fender panel for a structural fender of  claim 8 , wherein the thickness of the inner fender panel sections range from about 0.8 mm to about 1.5 mm. 
     
     
         10 . The inner fender panel for a structural fender of  claim 1 , wherein the abutting inner fender panel sections are joined to one another by a laser weld joint between them. 
     
     
         11 . The inner fender panel for a structural fender of  claim 10 , wherein the laser weld joint is configured to extend in a substantially vertical direction or a substantially axial direction when the inner fender panel is installed on an automotive vehicle. 
     
     
         12 . The inner fender panel for a structural fender of  claim 1 , wherein the a plurality of abutting inner fender panel sections comprise a door attachment section that abuts a central section that abuts a front attachment section, and wherein the central section has a thickness that is less than the door attachment section and the thickness of the front attachment section. 
     
     
         13 . A structural fender for an automotive vehicle, comprising:
 a formed outer panel having a viewable outer surface and an inner surface; and   a formed inner fender panel having an outer surface configured for attachment to the inner surface of the outer panel, and an inner surface; the inner fender panel comprising a plurality of abutting inner fender panel sections that are joined to one another, each inner fender panel section having a thickness, at least two abutting inner fender panel sections having thicknesses that are different.   
     
     
         14 . The structural fender of  claim 13 , wherein the outer surfaces of abutting inner fender panel sections having thicknesses that are different are substantially co-planar. 
     
     
         15 . The structural fender of  claim 13 , wherein each of the plurality of abutting inner fender panel sections comprise a metal sheet material having a material composition and each of the material compositions are the same. 
     
     
         16 . The structural fender of  claim 13 , wherein the plurality of abutting inner fender panel sections are joined to one another by laser weld joints. 
     
     
         17 . The structural fender of  claim 13 , wherein a plurality of abutting inner fender panel sections comprise a door attachment section that abuts a central section that abuts a front attachment section, and wherein the central section has a thickness that is less than the door attachment section and the thickness of the front attachment section. 
     
     
         18 . The structural fender of  claim 13 , wherein the structural fender comprises:
 a first front fender that is operably attached to a first end of a cross-car extending positioning and reinforcement structure having the first end and an opposed second end; and   a second fender that comprises a mirror image of the first front fender and is attached to the second end of the positioning and reinforcement structure, wherein the positioning and reinforcement structure is operable to a predetermined position of the first front fender and the second fender in relation to a front hood of the vehicle.   
     
     
         19 . A method of making an inner fender panel for a structural fender comprising an outer surface configured for attachment to the inner surface of an outer panel of the fender and an inner surface, the inner fender panel comprising a plurality of abutting inner fender panel sections that are joined to one another, each inner fender panel section having a thickness, at least two abutting inner fender panel sections having thicknesses that are different, comprising:
 forming a plurality of flat planar inner section blanks that are configured to abut one another and define an inner fender panel precursor, each inner section blank having a blank thickness, at least two abutting inner section blanks having thicknesses that are different;   joining abutting inner section blanks to form the inner fender panel precursor; and   stamping the inner fender panel precursor to plastically deform the inner fender panel blanks and form the inner fender panel.   
     
     
         20 . The method of  claim 19 , wherein forming the inner section blanks comprises forming a door attachment section blank that abuts a central section blank that abuts a front attachment section blank, and wherein the central section blank has a thickness that is less than the door attachment section blank and the front attachment section blank, and wherein joining comprises laser welding abutting blanks to form a laser weld joint between them.