Butt jointed closed section hollow structural element

Abstract

A vehicular structural member is provided from a closed section hollow element that utilizes a conventional clamshell configuration but eliminates the overlapped joint of the prior art. It has been proven that for large volume applications such as those dictated by the automotive industry, sheet metal press forming is the most cost-effective method of manufacturing structural components. The present disclosure eliminates the redundant material associated with overlapping or flange type joints in clamshell closed section hollow elements thereby reducing weight and cost.

What is claimed is: 
     
         1 . A closed section hollow element formed from sheet metal comprising:
 an upper sheet metal stamped component with a generally open section manufactured using press forming techniques and configured with two primarily parallel downstanding interface flanges;   a lower sheet metal stamped component with a generally open section manufactured using press forming techniques and configured with two primarily parallel upstanding interface flanges;   said upstanding and downstanding interface flanges being complimentarily trimmed after press forming so as to contact each other along an interface between the upper sheet metal stamped component and the lower sheet metal stamped component, and said interface being operatively configured as a butt welded structural attachment joint between the upper sheet metal stamped component and lower sheet metal stamped component thereby creating a continuous hollow structural element of a variable cross section.   
     
     
         2 . The closed section hollow element of  claim 1  wherein the upstanding and downstanding interface flanges of the upper sheet metal stamped component and the lower sheet metal stamped component are complementarily trimmed using five-axes laser cutting. 
     
     
         3 . The closed section hollow element of  claim 1  wherein the upper sheet metal stamped component and the lower sheet metal stamped component are structurally attached along the interface by a continuous laser butt weld. 
     
     
         4 . The closed section hollow element of  claim 2  wherein the upper sheet metal stamped component and the lower sheet metal stamped component are rigidly held in dimensional compliance while the upstanding and downstanding interface flanges are complementarily trimmed using five-axes laser cutting. 
     
     
         5 . The closed section hollow element of  claim 3  wherein the upper sheet metal stamped component and the lower sheet metal stamped component are rigidly held in dimensional compliance while being structurally attached along the interface by a continuous laser butt weld. 
     
     
         6 . A closed section hollow element formed from sheet metal comprising:
 an upper sheet metal stamped component with a substantially open section adapted to be manufactured using press forming techniques, the upper sheet metal stamped component configured with two primarily parallel downstanding interface flanges;   a lower sheet metal stamped component with a generally open section manufactured using press forming techniques and configured with two primarily parallel upstanding interface flanges;   said upper sheet metal stamped component and said lower sheet metal stamped component being operatively configured to be rigidly held in dimensional compliance while the upstanding and downstanding interface flanges are complementarily trimmed using five-axes laser cutting after press forming so as to contact each other along their entire interface;   said upper sheet metal stamped component and said lower sheet metal stamped component being operatively configured to be rigidly held in dimensional compliance while being structurally attached along the interface by a continuous laser butt weld thereby creating a continuous hollow structural element of a variable cross section.   
     
     
         7 . The closed section hollow element of  claim 6  wherein the upper sheet metal stamped component and the lower sheet metal stamped component are operatively configured to function as a vehicular suspension arm. 
     
     
         8 . The closed section hollow element of  claim 6  wherein the upper sheet metal stamped component and the lower sheet metal stamped component are operatively configured to function as a vehicular motor compartment rail. 
     
     
         9 . The closed section hollow element of  claim 6  wherein the upper sheet metal stamped component and the lower sheet metal stamped component are operatively configured to function as a beam for a vehicular suspension subframe.