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 . A method of forming an automotive vehicle structural fender, the method comprising:
 forming a plurality of panel sections, the plurality of panel sections having at least a first panel section having a first thickness and a second panel section having a second thickness, the second thickness being smaller than the first thickness;   welding the first panel section to the second panel section;   welding the second panel section to the remainder of the plurality of panel sections to form an fender panel precursor;   forming at least one opening in one of the first panel section and the second panel section, wherein the at least one opening is does not intersect a welded area; and   plastically deforming the fender panel precursor to form the structural fender.   
     
     
         2 . The method of  claim 1 , wherein the welding of the first panel section to the second panel section includes forming a first straight weld in a first direction. 
     
     
         3 . The method of  claim 2 , wherein the welding of the fender panel precursor to the remainder of the plurality of panel sections includes forming a second straight weld in a second direction. 
     
     
         4 . The method of  claim 3 , wherein the second direction being opposite the first direction. 
     
     
         5 . The method of  claim 4 , further comprising forming a third straight weld in a third direction, the third straight weld having a starting end proximate an end of the second straight weld, the third direction being different than the first direction and the second direction. 
     
     
         6 . The method of  claim 5 , further comprising performing the first straight weld, the second straight weld and the third straight weld sequentially. 
     
     
         7 . The method of  claim 3 , further comprising translating a laser during welding to form the first straight weld substantially parallel with the second straight weld. 
     
     
         8 . The method of  claim 1 , wherein the plurality of panel sections includes a third panel section having a third thickness, the third thickness being larger than the second thickness. 
     
     
         9 . The method of  claim 8 , further comprising welding the third panel section to the second panel section opposite the first panel section to form the fender panel precursor. 
     
     
         10 . The method of  claim 9 , wherein the first panel section is a front attachment section and the third panel section is a door attachment section. 
     
     
         11 . The method of  claim 10 , further comprising forming the door attachment section from two separate blanks. 
     
     
         12 . The method of  claim 3 , further comprising forming the first straight weld and the second straight weld with a laser. 
     
     
         13 . The method of  claim 1 , further comprising:
 forming a plurality of first panel blanks in a first sheet stock having a first width;   forming a plurality of second panel blanks in a second sheet stock having a second width, the first width being different from the second width;   selecting the first panel section from the plurality of first panel blanks; and   selecting the second panel section from the plurality of second panel blanks.   
     
     
         14 . The method of  claim 13 , wherein the step of forming the plurality of first panel blanks includes arranging the plurality of first panel blanks on the first sheet stock to reduce waste. 
     
     
         15 . The method of  claim 14 , wherein the step of forming the plurality of second panel blanks includes arranging the plurality of second panel blanks on the second sheet stock to reduce waste. 
     
     
         16 . The method of  claim 8 , further comprising:
 forming a plurality of first panel blanks in a first sheet stock having a first width;   forming a plurality of second panel blanks in a second sheet stock having a second width, the first width being different from the second width;   forming a plurality of third panel blanks in a third sheet stock having a third width, the third width being different from the first width and the second width;   selecting the first panel section from the plurality of first panel blanks;   selecting the second panel section from the plurality of second panel blanks; and   selecting the third panel section from the plurality of third panel blanks.   
     
     
         17 . A method of forming an automotive vehicle structural fender, the method comprising:
 forming a first panel section having a first thickness and a second panel section having a second thickness, the second thickness being smaller than the first thickness;   forming a third panel section having a third thickness, the third thickness being larger than the second thickness;   coupling the first panel section to the second panel section with a first straight weld formed by moving a laser in a first direction;   forming a fender panel precursor by coupling the second panel section to the third panel section on a side opposite the first panel section, the second panel section being coupled to the third panel section with a second straight weld formed by moving the laser in a second direction;   plastically deforming the fender panel precursor to form an inner fender panel having an outer surface;   forming an outer fender panel having an inner surface; and   attaching the outer surface to the inner surface to form a structural fender.   
     
     
         18 . The method of  claim 17  wherein the second direction is opposite the first direction. 
     
     
         19 . The method of  claim 17  wherein the second direction is parallel to the first direction. 
     
     
         20 . The method of  claim 17  further comprising coupling a fourth panel section to the third panel section with a third straight weld, the third straight weld being formed by moving the laser in a third direction, the third direction being on an angle relative to the second direction.