Method of manufacturing a sturctural ultra-thin sheet metal part with patch welded reinforcements

Abstract

A sheet metal component for a vehicle comprising a metal sheet having thickened portions integrated into the metal sheet that reinforces local areas of the sheet metal component. The metal sheet has integrally formed longitudinal members and cross-members. A method of manufacturing a sheet metal component is also disclosed that comprises selecting a planar sheet metal blank that is cut to size to define an outer contour. At least one reinforcing layer is provided on the blank to form thickened portions of the blank. The method also includes the steps of heating the blank, forming the blank into the desired geometric shape of the sheet metal component, and hardening the sheet metal component.

What is claimed is: 
     
         1 . A sheet metal component for a vehicle comprising:
 a metal sheet having thickened portions integrated into the metal sheet that reinforce local areas of the sheet metal component, wherein the metal sheet has integrally formed longitudinal members and cross-members.   
     
     
         2 . The sheet metal component of  claim 1  wherein the metal sheet is selected from a group consisting essentially of:
 boron steel; 
 FeMn steel; 
 FeAl steel; and 
 aluminum alloy. 
 
     
     
         3 . The sheet metal component of  claim 1  wherein the metal sheet is boron steel having a thickness of less than or equal to 0.7 mm. 
     
     
         4 . The sheet metal component of  claim 1  wherein the integrally formed longitudinal members further comprise at least one U-shaped channel formed in a longitudinal direction in the sheet metal component. 
     
     
         5 . The sheet metal component of  claim 1  wherein the cross-members further comprise at least one rib formed in a transverse direction in the sheet metal component. 
     
     
         6 . A method of manufacturing a sheet metal component comprising:
 selecting a planar sheet metal blank that is cut to size defining an outer contour;   providing at least one reinforcing layer to the blank to form thickened portions on the blank;   heating the blank;   forming the blank into a geometric shape of the sheet metal component; and   hardening the sheet metal component.   
     
     
         7 . The method of  claim 6  wherein the step of providing at least one reinforcing layer further comprises assembling small planar sheet metal plates to the blank and welding the small planar sheet metal plates to the blank. 
     
     
         8 . The method of  claim 6  wherein the step of providing at least one reinforcing layer further comprises assembling small planar sheet metal plates to the blank and pressing the small sheet metal plates into the blank. 
     
     
         9 . The method of  claim 6  wherein the step of providing at least one reinforcing layer further comprises rolling the reinforcing layer onto the blank by varying a roll gap.